Shipping system for temperature-sensitive materials

ABSTRACT

Shipping system for temperature-sensitive materials. In one embodiment, the shipping system may include an insulated container. The insulated container may include a frame surrounding a payload space, the frame including a door providing access to the payload space. The shipping system may additionally include a door brace assembly. The door brace assembly may be mounted within the payload space just inside the door and may include a door plug configured to substantially close the payload space. The door brace assembly may additionally include a door brace mounted within the door plug. The door brace may be transformable between a retracted state and an expanded state. When in its retracted state, the door brace assembly may be loaded into or removed from the insulated container. When in its expanded state, the door brace assembly engages the four corners of the frame just inside the door to keep the frame square.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Pat. Application No. 63/319,262, inventors James R. Chasteen et al., filed Mar. 11, 2022, the disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates generally to shipping systems for temperature-sensitive materials and relates more particularly to a novel such shipping system.

Shipping systems of the type that may be used to store and/or to transport payloads of temperature-sensitive materials, such as, but not limited to, biological materials, pharmaceutical products, foods, beverages, and/or medical devices, are well-known. Such systems must be capable of maintaining the temperature-sensitive materials within a desired temperature range for an extended period of time (e.g., up to one or more days or longer). As can readily be appreciated, the maintenance of temperature-sensitive materials within a desired temperature range can be challenging and typically cannot be met simply by placing the temperature-sensitive materials in a thermally insulating container. One way in which such temperature maintenance may be achieved is by the use of active temperature-control devices, such as electrically-powered refrigeration units or the like. Systems that include active temperature-control devices are sometimes referred to as actively-controlled systems. A disadvantage with actively-controlled systems is that they tend to add considerable expense to transportation costs. This is, in part, because such systems typically require, amongst other things, a portable source of electricity.

Another way in which temperature maintenance may be achieved is by the use of passive temperature-control devices, such as, but not limited, to ice packs, gel packs, and the like. Such passive temperature-control devices typically comprise a quantity of a phase-change material disposed within a suitable container. Many different types of phase-change materials exist, some types comprising an organic phase-change material and some other types comprising an aqueous phase-change material. As an alternative to packaged phase-change materials, loose ice or loose dry ice may also be used. Shipping systems that rely on passive temperature-control are sometimes referred to as passively-controlled systems.

Some passively-controlled systems for shipping temperature-sensitive materials are designed for shipping a parcel-sized payload. Other passively-controlled systems for shipping temperature-sensitive materials are designed for shipping a pallet-sized payload.

Illustrative examples of passively-controlled shipping systems that may be used to transport pallet-sized payloads are discussed below.

In U.S. Pat. Application Publication No. US 2017/0121097 A1, inventors Pranadi et al., published May 4, 2017, which is incorporated herein by reference, there is disclosed a thermally insulated shipping system for use in transporting a pallet-sized payload. In one embodiment, the system includes a plurality of thermally insulating walls arranged to define an interior volume suitable for receiving a pallet-sized payload. The thermally insulating walls include a top wall, a bottom wall, a front wall, a rear wall, a left wall, and a right wall, of which all but the bottom wall include at least two slots facing towards the interior volume. One of the slots is an inner slot that is more proximal to the interior volume, and one of the slots is an outer slot that is more distal to the interior volume. The system also includes a plurality of inner cassettes disposed in at least some of the inner slots and a plurality of outer cassettes disposed in at least some of the outer slots. The inner and outer cassettes include phase-change materials.

In U.S. Pat. Application Publication No. US 2016/0362240 A1, inventor Ferracamo, Jr., published Dec. 15, 2016, and which is incorporated herein by reference, there is disclosed a passive temperature controlled container for passively maintaining a specified temperature range in a storage chamber of the container for a predetermined amount of time. The passive temperature controlled container may be configured to have an inner PCM layer and an outer PCM layer, with an air chamber layer between the two PCM layers to allow for the free movement of air around all six sides of the container.

In U.S. Pat. No. 9,180,998 B2, inventor Banks et al., which issued Nov. 10, 2015, and which is incorporated herein by reference, there is disclosed an insulated pallet shipper and methods of making and using the same. The insulated pallet shipper of the foregoing published patent application is said to include an insulated container shaped to include a top wall, a bottom wall, a left side wall, a right side wall, a rear wall, and a front wall, the aforementioned walls collectively defining a cavity. A plurality of coolant members are positioned within the cavity, each of the coolant members including a plurality of coolant bricks encased within a cardboard container. At least some of the coolant members are preconditioned at a refrigerating temperature and at least some of the coolant members are preconditioned at a freezing temperature. An inner pallet is seated on the bottom wall.

In U.S. Pat. Application Publication No. US 2007/0051734 A1, inventor Kuhn, published Mar. 8, 2007, and which is incorporated herein by reference, there is disclosed a thermally insulated container, in particular for shipping purposes, the thermally insulated container having a container wall which completely encloses an interior space, wherein the interior space has at least one closable opening and is insulated with at least one vacuum insulation element to prevent heat exchange. At least one passive melt-storage element that is filled with a melt-storage material is provided in the container.

Documents that may be of interest may include the following, all of which are incorporated herein by reference: U.S. Pat. No. 9,963,287 B2, inventors Vogel et al., issued May 8, 2018; U.S. Pat. No. 9,718,608 B2, inventors Tattam et al., issued Aug. 1, 2017; U.S. Pat. No. 8,763,423 B2, inventor Tattam, issued Jul. 1, 2014; U.S. Pat. No. 8,672,137 B2, inventors Seagle et al., issued Mar. 18, 2014; U.S. Pat. No. 7,913,511 B2, inventors Meyer et al., issued Mar. 29, 2011; U.S. Pat. No. 7,784,301 B2, inventors Sasaki et al., issued Aug. 31, 2010; U.S. Pat. No. 7,028,504 B2, inventor Derifield, issued Apr. 18, 2006; U.S. Pat. No. 6,832,562 B2, inventors Tabor et al., issued Dec. 21, 2004; U.S. Pat. No. 5,669,233, inventors Cook et al., issued Sep. 23, 1997; U.S. Pat. Application Publication No. US 2018/0093816 A1, inventors Longley et al., published Apr. 5, 2018, U.S. Pat. Application Publication No. US 2015/0276297 A1, inventors Moore et al., published Oct. 1, 2015; U.S. Pat. Application Publication No. US 2015/0239639 A1, inventors Wenner et al., published Aug. 27, 2015; U.S. Pat. Application Publication No. US 2013/0015191 A1, inventors Seagle et al., published Jan. 17, 2013; U.S. Pat. Application Publication No. US 2010/0301057 A1, inventors Tattam et al., published Dec. 2, 2010; PCT International Publication No. WO 2018/213348 A2, published Nov. 26, 2018; PCT International Publication No. WO 2014/083320 A1, published Jun. 5, 2014; PCT International Publication No. WO 2014/023911 A1, published Feb. 13, 2014; French Pat. Application Publication No. FR 2 994 420 A1, published Feb. 14, 2014; and French Pat. Application Publication No. FR 2 989 359 A1, published Oct. 18, 2013.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a novel shipping system for temperature-sensitive materials.

Therefore, according to one aspect of the invention, there is provided a shipping system for temperature-sensitive materials, the shipping system comprising (a) an insulated container, the insulated container having a payload space dimensioned to accommodate a payload and further having a door leading to the payload space; and (b) a door plug assembly, the door plug assembly being positioned within the payload space just inside the door, the door plug assembly comprising a plug and a first backing sheet, the plug being thermally insulating and dimensioned to substantially close the payload space when the door is open, the first backing sheet coupled to the plug to provide stiffening support thereto.

In a more detailed feature of the invention, the shipping system may be a passively-controlled shipping system.

In a more detailed feature of the invention, the door plug assembly may be removable from the insulated container.

In a more detailed feature of the inventio, the first backing sheet may be secured to a front surface of the plug.

In a more detailed feature of the invention, the first backing sheet may be secured to a rear surface of the plug.

In a more detailed feature of the invention, the door plug assembly may further comprise a second backing sheet, the first backing sheet may be secured to a front surface of the plug, and the second backing sheet may be secured to a rear surface of the plug.

In a more detailed feature of the invention, the plug may comprise one or more pieces of flexible foam insulation.

In a more detailed feature of the invention, the first backing sheet may comprise corrugated polypropylene.

In a more detailed feature of the invention, the plug may comprise at least one transverse opening.

In a more detailed feature of the invention, the at least one transverse opening may comprise a handle opening.

In a more detailed feature of the invention, the shipping system may further comprise a handle insert, and the handle insert may be disposed within the handle opening and may be configured to receive a hand of a user.

In a more detailed feature of the invention, the shipping system may further comprise a handle insert plug, and the handle insert plug may be disposed within the handle insert to minimize air flow through the handle insert.

In a more detailed feature of the invention, the first backing sheet may be secured to a front surface of the plug and may comprise an opening aligned with the handle opening of the plug.

In a more detailed feature of the invention, the at least one transverse opening may comprise a data logger opening.

In a more detailed feature of the invention, the shipping system may further comprise a data logger holder, and the data logger holder may be disposed within the data logger opening.

In a more detailed feature of the invention, the shipping system may further comprise a data logger holder plug, and the data logger holder plug may be disposed within the data logger holder to minimize air flow through the data logger holder.

In a more detailed feature of the invention, the first backing sheet may be secured to a front surface of the plug and may comprise an opening aligned with the data logger holder.

In a more detailed feature of the invention, the insulated container may further comprise a kickstand mounted on the door, the first backing sheet may be secured to a front surface of the plug, and the first backing sheet may be configured to include a recess for receiving the kickstand.

In a more detailed feature of the invention, the insulated container may further comprise a strap terminating in a buckle and may further comprise a receiver, and the plug may be shaped to include a recess to permit access to the receiver by buckle.

According to another aspect of the invention, there is provided a kit, the kit comprising (a) an insulated container, the insulated container having a payload space dimensioned to accommodate a payload and further having a door leading to the payload space; (b) a door plug, the door plug being thermally insulating and dimensioned to substantially close the payload space when the door is open, the door plug having a first transverse opening; (c) a first data logger holder, the first data logger holder being dimensioned to matingly receive a first type of data logger; and (d) a second data logger holder, the second data logger holder being dimensioned to matingly receive a second type of data logger, the second type of data logger having different outer dimensions than the first type of data logger; (e) wherein the first data logger holder and the second data logger holder have the same outer dimensions and are alternatively mountable in the first transverse opening of the plug.

In a more detailed feature of the invention, the kit may further comprise a first data logger holder plug and a second data logger holder plug, the first data logger holder plug may be mountable within the first data logger holder, and the second data logger holder plug may be mountable within the second data logger holder.

In a more detailed feature of the invention, the door plug may comprise at least one piece of flexible foam insulation.

In a more detailed feature of the invention, the shipping system may further comprise at least one of a first backing sheet secured to a front surface of the door plug and a second backing sheet secured to a rear surface of the door plug.

According to still another aspect of the invention, there is provided a shipping system for temperature-sensitive materials, the shipping system comprising (a) an insulated container, the insulated container comprising a frame surrounding a payload space, the frame including a door providing access to the payload space; and (b) a door brace, the door brace removably mounted within the payload space just inside the door, the door brace configured to keep the frame square.

In a more detailed feature of the invention, the shipping system may be a passively-controlled shipping system.

In a more detailed feature of the invention, the shipping system may be a pallet-sized shipping system.

In a more detailed feature of the invention, the shipping system may further comprise a door plug, and the door plug may be thermally insulating and dimensioned to substantially close the payload space when the door is open.

In a more detailed feature of the invention, the door plug may comprise a plurality of assembled pieces of foam insulation.

In a more detailed feature of the invention, the door brace may be mounted within the door plug.

In a more detailed feature of the invention, the door plug may comprise a transverse opening, the shipping system may further comprise a data logger holder, and the data logger holder may be mounted in the transverse opening.

In a more detailed feature of the invention, the door brace may comprise a first strut and a second strut, the door brace may further comprise a first corner piece, a second corner piece, a third corner piece, and a fourth corner piece, the first corner piece may be fixedly mounted at a bottom end of the first strut, the second corner piece may be fixedly mounted at a bottom end of the second strut, the third corner piece may be coupled to a top end of the first strut with a reverse action clamp, and the fourth corner piece may be coupled to a top end of the second strut with a reverse action clamp.

In a more detailed feature of the invention, the first strut and the second strut may be joined in a scissoring configuration.

For purposes of the present specification and claims, various relational terms like “top,” “bottom,” “proximal,” “distal,” “upper,” “lower,” “front,” and “rear” may be used to describe the present invention when said invention is positioned in or viewed from a given orientation. It is to be understood that, by altering the orientation of the invention, certain relational terms may need to be adjusted accordingly.

Additional objects, as well as aspects, features and advantages, of the present invention will be set forth in part in the description which follows, and in part will be obvious from the description or may be learned by practice of the invention. In the description, reference is made to the accompanying drawings which form a part thereof and in which is shown by way of illustration various embodiments for practicing the invention. The embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural or other changes may be made without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense.

BRIEF DESCRIPTION OF THE DRAWINGS

The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

The accompanying drawings, which are hereby incorporated into and constitute a part of this specification, illustrate various embodiments of the invention and, together with the description, serve to explain the principles of the invention. These drawings are not necessarily drawn to scale, and certain components may have undersized and/or oversized dimensions or may be missing for purposes of explication. In the drawings wherein like reference numerals represent like parts:

FIG. 1A is a front perspective view of a first embodiment of a shipping system for temperature-sensitive materials constructed according to the present invention;

FIG. 1B is a partly exploded bottom view of the shipping system shown in FIG. 1A;

FIG. 1C is a partly exploded front perspective view of the shipping system shown in FIG. 1A, the shipper of the shipping system being shown with its door in an open position;

FIGS. 2A and 2B are front and rear perspective views, respectively, of the shipper shown in FIG. 1C, the shipper being shown with its door in an open position;

FIG. 2C is a partly exploded perspective of the shipper shown in FIG. 1C;

FIGS. 3A and 3B are front and rear perspective views, respectively, of the frame of the shipper shown in FIG. 1C, the frame being shown with its door in a closed position;

FIGS. 4A and 4B are top and bottom perspective views, respectively, of the frame bottom shown in FIG. 3A;

FIGS. 5A and 5B are top and bottom perspective views, respectively, of the frame top shown in FIG. 3A;

FIGS. 6A through 6C are front, rear perspective, and rear views, respectively, of the frame door shown in FIG. 3A;

FIGS. 7A and 7B are front and rear perspective views, respectively, of the frame back shown in FIG. 3B;

FIGS. 8A and 8B are right and left perspective views, respectively, of the frame left side shown in FIG. 3B;

FIGS. 9A and 9B are right and left perspective views, respectively, of the frame right side shown in FIG. 3A;

FIGS. 10A and 10B are front and rear perspective views, respectively, of the left corner gusset shown in FIG. 3B;

FIGS. 11A and 11B are front and rear perspective views, respectively, of the right corner gusset of the shipper shown in FIG. 3A;

FIG. 12 is a front view of the low-profile, high-strength door hinge shown in FIG. 2A;

FIG. 13 is an alternative door hinge that may be used, instead of the door hinge of FIG. 12 , in the shipper of FIG. 2A;

FIG. 14A is an enlarged fragmentary front right perspective view of the shipper of FIG. 2A, showing the door-latching mechanism with the shipper in a closed position;

FIGS. 14B and 14C are enlarged fragmentary front right and enlarged fragmentary front left perspective views, respectively, of the shipper of FIG. 2A, with certain components removed to reveal additional details of the door-latching mechanism;

FIGS. 14D and 14E are enlarged perspective and partly exploded enlarged perspective views, respectively, of the door-latching mechanism shown in FIG. 14A;

FIGS. 14F and 14G are enlarged fragmentary perspective views of the door-latching mechanism shown in FIG. 14A, showing one of the plate assemblies and the rack-and-pinion/handle assembly, respectively;

FIGS. 15A and 15B are front perspective and rear perspective views, respectively, of the first shell portion for the shipper shown in FIG. 2A;

FIGS. 16A and 16B are front perspective and rear perspective views, respectively, of the second shell portion for the shipper shown in FIG. 2A;

FIGS. 17A and 17B are bottom and top perspective views, respectively, of the shipper shown in FIG. 2A, with many of the heat-spreader assemblies not being shown to reveal components that would otherwise be obscured thereby;

FIG. 17C is a partly exploded perspective view of the shipper shown in FIG. 2A, with certain components not being shown for simplicity;

FIG. 17D is an enlarged fragmentary perspective view of the shipper shown in FIG. 2A, with the top panel of the heat-spreader assembly shown pivoted away from the door to reveal components that would otherwise be obscured thereby;

FIG. 17E is a perspective view of the shipper shown in FIG. 2A, with the top panel of the heat-spreader assembly shown pivoted away from the door and with certain components not being shown for simplicity;

FIG. 17F is an enlarged fragmentary perspective view of the shipper shown in FIG. 2A, showing some of the top PCM assemblies and top heat-spreaders mounted on the top;

FIGS. 18A through 18D are perspective views showing how the bottom PCM assemblies and bottom heat-spreader assemblies are mounted on the bottom;

FIG. 19A is a fragmentary perspective view of the shipper of FIG. 2A, showing the pair of payload retaining members, the free ends of the payload retaining members positioned on top of the shipper;

FIG. 19B is an enlarged fragmentary perspective view, showing the attachment of the fixed ends of the payload retaining members to the frame along its back bottom edge;

FIG. 19C is an enlarged fragmentary perspective view, showing a receptacle in the bottom of the frame for receiving the free end of a payload retaining member;

FIG. 19D is an enlarged fragmentary perspective view, showing the buckle at the free end of a payload retaining member;

FIG. 19E is an enlarged fragmentary perspective view, showing the buckle at the free end of a payload retaining member secured to a receptacle;

FIG. 19F is an enlarged fragmentary perspective view, showing a payload secured with the payload retaining members;

FIGS. 20A and 20B are perspective and exploded perspective views, respectively, of the door plug assembly shown in FIG. 1C;

FIGS. 21A through 21C are front perspective, rear, and bottom views, respectively, of the plug shown in FIG. 20A;

FIGS. 22A and 22B are front perspective and front views, respectively, of the front backing sheet shown in FIG. 20A;

FIGS. 23A and 23B are front perspective and rear views, respectively, of the rear backing sheet shown in FIG. 20B;

FIGS. 24A, 24B, and 24C are front perspective, rear, and bottom views, respectively, of the handle insert shown in FIG. 20B;

FIGS. 25A, 25B, and 25C are front perspective, rear, and bottom views, respectively, of the handle insert plug shown in FIG. 20B;

FIGS. 26A, 26B, and 26C are front perspective, rear, and bottom views, respectively, of the data logger holder shown in FIG. 20B;

FIGS. 27A, 27B, and 27C are front perspective, rear, and bottom views, respectively, of the data logger holder plug shown in FIG. 20A;

FIGS. 28A, 28B, and 28C are front perspective, rear, and bottom views, respectively, of the receiver recess plug shown in FIG. 20A;

FIG. 29 is a front perspective view of an alternative data logger holder to the data logger holder shown in FIG. 26A;

FIG. 30 is a front perspective view of an alternative data logger holder plug to the data logger holder plug shown in FIG. 27A;

FIG. 31 is a partly exploded perspective view of a second embodiment of a shipping system for temperature-sensitive materials constructed according to the present invention, the shipper of the shipping system shown with its door in an open state and with one of its bottom heat-spreader assemblies in an open state;

FIGS. 32A through 32D are enlarged front perspective, front, rear, and right side views, respectively, of the door brace assembly shown in FIG. 31 ;

FIGS. 32E and 32F are enlarged front perspective and rear perspective views, respectively, of the door brace assembly shown in FIG. 31 , with the front and rear backing sheets and portions of the plug not being shown to reveal other components obscured thereby;

FIGS. 33A and 33B are enlarged front perspective and rear perspective views, respectively, of the door plug shown in FIG. 32A;

FIGS. 34A and 34B are front perspective and partly exploded perspective views, respectively, of the door brace shown in FIG. 31 ;

FIG. 35 is an enlarged fragmentary longitudinal section view of one of the struts of the door brace shown in FIG. 34A;

FIG. 36 is a partly exploded side view of the reverse action clamp assembly shown in FIG. 31 ;

FIGS. 37A and 37B are enlarged front perspective and rear perspective views, respectively, of the front backing sheet shown in FIG. 32A;

FIGS. 38A and 38B are enlarged rear perspective and front perspective views, respectively, of the rear backing sheet shown in FIG. 32C; and

FIG. 39 is a front perspective view of the door brace assembly of FIG. 31 , with the handles in the retracted position.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed at a new shipping system for temperature-sensitive materials. The shipping system of the present invention may comprise, amongst other things, a pallet-sized shipping system that is similar to that disclosed in U.S. Patent Application Publication No. US 2021/0070539 A1, inventors Chasteen et al., which was published Mar. 11, 2021, and which is incorporated herein by reference. Notwithstanding the above, it is to be understood that the present invention is not limited to a system that includes a pallet-sized shipping system of the type that is disclosed in U.S. Patent Application Publication No. US 2021/0070539 A1 and may include other types of shipping systems, whether pallet-sized shipping systems or otherwise.

According to one aspect of the invention, the shipping system may further comprise a door plug assembly that may be used to plug, either partially or substantially completely, an opening leading to the payload cavity of the shipping system. In at least one embodiment, the door plug assembly may be configured to be mounted within the payload cavity of the shipping system just interior to the door of the shipping system. In at least one embodiment, the door plug assembly may comprise, amongst other things, a plug. In at least one embodiment, the plug may be dimensioned to substantially close at least a portion of an end of the payload cavity that may be covered by the door and preferably may close substantially the entirety of the end of the payload cavity that may be covered by the door. Consequently, the plug may improve the thermal insulating properties of the shipping system by providing additional insulation proximate to the door. In at least one embodiment, the plug may consist of or comprise one or more pieces of a foam material that may include, but is not limited to, expanded polystyrene foam, polyurethane foam, and/or expanded polypropylene foam.

In at least one embodiment, the plug may comprise one or more transverse cutouts or recesses. In at least one embodiment, the one or more transverse cutouts may comprise at least one handle cutout. In at least one embodiment, a handle insert may be removably or permanently mounted within each handle cutout, and the handle insert may be appropriately configured with an opening dimensioned so that a portion of a hand may be insertable into the handle insert to facilitate the mounting, removal and/or movement of the door plug assembly by a user. In at least one embodiment, a handle insert plug may be removably or permanently mounted within the rear of each handle insert opening to minimize thermal loss through the opening of the handle insert.

In at least one embodiment, the one or more transverse cutouts may additionally or alternatively comprise a data logger cutout. In at least one embodiment, a data logger holder or insert may be removably or permanently mounted within the data logger cutout, and the data logger insert may be appropriately configured with an opening dimensioned to snugly receive a data logger. In at least one embodiment, a data logger insert plug may be removably or permanently mounted within the rear of the data logger insert opening to minimize thermal loss through the opening of the data logger insert. In at least one embodiment, a plurality of different data logger inserts may be provided, wherein each data logger insert is configured with an opening dimensioned to receive a different type of data logger, the plurality of data logger inserts being configured to be alternatively mounted within the data logger cutout.

In at least one embodiment, the one or more transverse cutouts may additionally or alternatively comprise one or more strap attachment receiver cutouts configured so as not to cover the one or more strap attachment receivers on the bottom wall of the shipping system. In at least one embodiment, a plug may be removably or permanently mounted within the front of each of the one or more strap attachment receiver cutouts to minimize thermal loss through the corresponding strap attachment receiver cutout.

In at least one embodiment, the plug may be supported by a front supporting or backing sheet and a rear supporting or backing sheet. In at least one embodiment, the plug may be sandwiched between a front backing sheet and a rear backing sheet. In at least one embodiment, each of the supporting sheets may consist of or comprise a rigid material, such as, but not limited to, a sheet of polypropylene or a similar material. In at least one embodiment, the front supporting sheet may comprise one or more transverse cutouts or recesses. In at least one embodiment, at least one of the one or more transverse cutouts of the front supporting sheet may be an integral, pop-out handle, and the integral, pop-out handle may be aligned with a corresponding handle cutout of the plug. In at least one embodiment, the one or more transverse cutouts of the front supporting sheet may additionally or alternatively comprise a data logger opening, and the data logger opening may be aligned with the data logger cutout of the plug. In at least one embodiment, the one or more transverse cutouts of the front supporting sheet may additionally or alternatively comprise a cutout configured to accommodate some or all of a kickstand that may be mounted on the inside of the door of the shipping system.

In at least one embodiment, the rear supporting sheet may be shaped to include one or more transverse cutouts or recesses. In at least one embodiment, at least one of the one or more transverse cutouts of the rear supporting sheet may be a cutout aligned with a corresponding strap attachment receiver cutout on the plug. In at least one embodiment, at least one of the one or more transverse cutouts of the rear supporting sheet may additionally or alternatively be one or more cutouts aligned with the data logger cutout of the plug. In this manner, a thermocouple or the like that is attached to a data logger mounted in the plug may pass from the plug into the payload cavity.

Referring now to FIGS. 1A through 1C, there are shown various views of a first embodiment of a shipping system for temperature-sensitive materials, the shipping system being constructed according to the teachings of the present invention and being represented generally by reference numeral 11. Details of shipping system 11 that are discussed elsewhere in this application or that are not critical to an understanding of the invention may be omitted from one or more of FIGS. 1A through 1C and/or from the accompanying description herein or may be shown in one or more of FIGS. 1A through 1C and/or described herein in a simplified manner.

Shipping system 11 may be well-suited for, but not limited to, freight aircraft shipments (including, but not limited to, international freight aircraft shipments) of temperature-sensitive materials, such as, but not limited to, biological materials, pharmaceutical products, foods, beverages, and/or medical devices. In particular, shipping system 11 may be designed to maintain temperature-sensitive materials within a desired temperature range (for example, but not limited to, a temperature range of +2° C. to +8° C. or a temperature range of +15° C. to +25° C. or below a temperature of approximately -15° C. or below a temperature of approximately -20° C.) for an extended period of time (for example, but not limited to, several hours or days including 96 hours or longer). In one embodiment, shipping system 11 may be qualified with ISTA (International Safe Transit Association) 7D standard temperature test profiles for a 96-hour duration.

In addition, shipping system 11 may be dimensioned to alternatively accommodate either a standard US-sized pallet and payload or a standard European-sized pallet and payload. A standard US-sized pallet typically has a footprint of 40 inches x 48 inches and a height of 5 inches. A standard European-sized pallet typically has a footprint of 31.5 inches x 47.2 inches and a height of 5 inches. In a preferred embodiment, shipping system 11 may be dimensioned to accommodate either a standard US-sized pallet or a standard European-sized pallet, together with a payload having a height of 45 inches (in other words, a combined pallet and payload height of 50 inches). In addition, in a preferred embodiment, shipping system 11 may have overall outer dimensions of about 61 ¼ inches x about 47 ¼ inches x about 62 ½ inches. In this manner, four such shipping systems 11 may simultaneously sit, in one layer, on a single PMC sheet having a footprint of 125 inches x 96 inches. In addition, by having overall outer dimensions of about 61 ¼ inches x about 47 ¼ inches x about 62 ½ inches, shipping system 11 may fit through a cargo hold door opening that is 64 inches in height.

As can be seen, for example, in FIG. 1C, shipping system 11 may comprise a shipper 13 and a door plug assembly 15, wherein door plug assembly 15 may be removably mounted within the payload cavity of shipper 13, preferably proximate to the end of the payload cavity near the shipper door. In certain applications, door plug assembly 15 may be omitted from shipping system 11.

Shipper 13 may be similar or identical to shipping system 11 of U.S. Pat. Application Publication No. US 2021/0070539 A1. As can be seen in FIGS. 2A and 2B, shipper 13 may comprise a bottom portion 17, a top portion 19, a rear portion 21, a door portion 23, a left side portion 25, and a right side portion 27, all of which may collectively define a substantially enclosed space 29. Space 29 may be designed to receive door plug assembly 15 and additionally to alternatively receive either a standard US-sized pallet and payload or a standard European-sized pallet and payload. In other words, space 29 may have “one size fits all” dimensions (i.e., may be universally suitable for) (1) a standard US-sized pallet and payload and (2) a standard European-sized pallet and payload.

As can be seen in FIG. 2C, each of bottom portion 17, top portion 19, rear portion 21, door portion 23, left side portion 25, and right side portion 27, may be formed by a plurality of layered components. One such component may be a frame 31, which can be seen best in FIGS. 3A and 3B. Frame 31 may, in turn, comprise a bottom 33, a top 35, a door (or front) 37, a back 39, a left side 41, a right side 43, a left corner gusset 45, and a right corner gusset 47.

Back 39 may be fixedly secured, for example, by an appropriate adhesive, by mechanical fasteners, or by other suitable means, to each of left side 41 and right side 43. Each of back 39, left side 41, and right side 43 may be fixedly secured, for example, by an appropriate adhesive, by mechanical fasteners or by other suitable means, to each of bottom 33 and top 35. Left corner gusset 45 may be fixedly secured, for example, by an appropriate adhesive, by mechanical fasteners, or by other suitable means, to each of left side 41, bottom 33, and top 35. Right corner gusset 47 may be fixedly secured, for example, by an appropriate adhesive, by mechanical fasteners, or by other suitable means, to each of right side 43, bottom 33, and top 35. In a preferred embodiment, the various components of frame 31 discussed above may be fixedly secured to one another using a bonding adhesive, such as PLEXUS MA2015, a two-part methacrylate adhesive (ITW Performance Polymers, Danvers, MA).

Preferably, each of bottom 33, top 35, door 37, back 39, left side 41, right side 43, left corner gusset 45, and right corner gusset 47 may be made of one or more materials possessing one or more of the following properties: low thermal conductivity and good mechanical strength. Examples of materials possessing at least one of these properties include, but are not limited to, metals (such as, for example, aluminum), metal alloys (such as, for example, steel), and composite materials. Composite materials are a class of materials that include a fiber material bonded together with a resin binder. The fiber material, which is typically e-glass, carbon, or aramid, may be arranged in a single layer or in a multi-layer with unidirectional or oriented layups depending on the desired properties. Examples of composite materials include fiberglass composite, carbon fiber composite, and Kevlar composite. Composite materials not only possess good mechanical strength but also exhibit low thermal conductivity. For example, fiberglass composite has a thermal conductivity of about 0.187 W/mKand carbon fiber composite has a thermal conductivity of about 0.275 W/mK. By contrast, aluminum has a thermal conductivity of about 167 W/mK, and steel has a thermal conductivity of about 52 W/mK. Consequently, composite materials, such as fiberglass composite and carbon fiber composite, may be preferred over metals and metal alloys, such as aluminum and steel, for forming bottom 33, top 35, door 37, back 39, left side 41, right side 43, left corner gusset 45, and right corner gusset 47.

In a preferred embodiment, the composite material used to make the foregoing components of frame 31 may be a multilayer material comprising 6 oz. e-glass layers (e.g., HEXFORCE 3733 fiber glass fabric, Hexcel Corporation, Stamford, CT) and 36 oz. e-glass layers (e.g., VECTOR-PLY E-TLY 3600, Vectorply Corporation, Phenix City, AL), as well as a matting (e.g., ROVICORE C2/300, Chromarat North America, Anderson, SC) and a resin (e.g, a vinyl ester/dicyclopentadiene blend infusion resin). Each of the components of frame 31 may have a wall thickness of about 3 mm to 6 mm.

Bottom 33, which is also shown separately in FIGS. 4A and 4B, may be a unitary (i.e., one-piece), solid structure and may be made of a molded composite material, such as a molded fiberglass composite or a molded carbon fiber composite. Bottom 33, which may be generally rectangular in overall shape, may be shaped to include a platform 54, which is preferably dimensioned to support a pallet (either with or without an accompanying payload on said pallet). Platform 54 may be shaped to include a plurality of open-topped depressions or troughs 56-1 through 56-4, each of which may be used to receive phase-change material in the manner to be discussed below. Although four troughs 56 are shown in the present embodiment, the number of troughs is not critical to the present invention; consequently, there may be greater than four troughs 56 or as few as one trough 56. Also, although troughs 56-1 through 56-4 are shown in the present embodiment having a particular size, shape, and orientation, it is to be understood that one or more of the size, shape, and orientation of troughs 56-1 through 56-4 may vary from what is shown in the present embodiment.

Bottom 33 may also be shaped to include a front border portion 58-1, a rear border portion 58-2, a left side border portion 58-3, a right side border portion 58-4, and a peripheral flange 58-5. A pair of recesses 59-1 and 59-2 may be provided in platform 54 along front border portion 58-1. As will be discussed further below, each of recesses 59-1 and 59-2 may be used to hold a receiver or bar to which a strap buckle may be attached. Each of rear border portion 58-2, left side border portion 58-3, and right side border portion 58-4 may be a double-walled structure including an inner surface extending upwardly relative to platform 54 and an outer surface extending both upwardly and downwardly relative to platform 54 (the inner surface extending upwardly relative to platform 54, the portion of the outer surface extending upwardly relative to platform 54, and the connecting surface between the foregoing inner and outer surfaces collectively forming a structural lip 60). By contrast, front border portion 58-1 preferably does not include any surfaces extending upwardly relative to platform 54; consequently, in this manner, a pallet and payload may be loaded onto or removed from platform 54 through the front (e.g., door 37) of shipper 13. Rear border portion 58-2 of bottom 33 may include recesses 62 to accommodate the tines of a forklift.

Rear border portion 58-2 may be appropriately dimensioned so that back 39 may be seated thereon and mounted thereto, for example, using an adhesive, mechanical fasteners, or other suitable means. In a similar fashion, left side border portion 58-3 may be appropriately dimensioned so that left side 41 and left corner gusset 45 may be seated thereon and mounted thereto, for example, using an adhesive, mechanical fasteners, or other suitable means, and right side portion 58-4 may be appropriately dimensioned so that right side 43 and right corner gusset 47 may be seated thereon and mounted thereto, for example, using an adhesive, mechanical fasteners, or other suitable means.

The underside of platform 54, front border portion 58-1, rear border portion 58-2, left side border portion 58-3, and right side border portion 58-4 of bottom 33 may be appropriately dimensioned to collectively form an open-bottomed space within which a plurality of vacuum insulated panels may be positioned.

Peripheral flange 58-5, which may extend outwardly from front border portion 58-1, rear border portion 58-2, left side border portion 58-3, and right side border portion 58-4, may be appropriately dimensioned so that other components of shipper 13, such as, for example, vacuum insulated panels, may be seated thereon.

Bottom 33 may include one or more thermal conduction breaks. More specifically, each of rear border portion 58-2, left side border portion 58-3, and/or right side border potion 58-4 may be shaped to include one or more through openings in their respective outer walls. In addition, front border portion 58-1 may be shaped to include one or more openings in its wall extending downwardly from platform 54. Such openings may serve as thermal conduction breaks to reduce the thermal conductivity of bottom 33 (since air has less thermal conductivity than the material used to make bottom 33) and may reduce the flow of heat into or out of space 20. In the present embodiment, such openings are formed only in the respective outer walls of border portions 58-2 through 58-4 and are not present in the respective inner walls of border portion 58-2 through 58-4 (border portion 58-1 not being double-walled); however, such openings could additionally or alternatively be present in such inner walls.

More specifically, in the present embodiment, front border portion 58-1 of bottom 33 may be shaped to include one or more through openings 70, rear border portion 58-2 of bottom 33 may be shaped to include one or more through openings 72 in its outer wall 73, left side border portion 58-3 of bottom 33 may be shaped to include one or more through openings 74 in its outer wall 75, and right side border portion 58-4 may be shaped to include one or more through openings 76 in its outer wall 77. The size, number and spacing of openings 70, 72, 74 and 76 may be similar to that disclosed in U.S. Pat. Application Publication No. US 2021/0070539 A1 or may be varied as desired.

Top 35, which is also shown separately in FIGS. 5A and 5B, may be a unitary, solid structure and may be made of a molded composite material, such as a molded fiberglass composite or a molded carbon fiber composite. Top 35, which may be generally rectangular in overall shape, may be shaped to include an inner portion 80 and an outer portion 82. Inner portion 80 may be shaped to include a plurality of open-bottomed depressions or troughs 84-1 and 84-2, which may be used to receive phase-change material in the manner to be discussed below. Troughs 84-1 and 84-2 may be accessible from the underside of top 35 and may be shaped to protrude upwardly from the remainder of inner portion 80. Although two troughs 84 are shown in the present embodiment, the number of troughs is not critical to the present invention; consequently, there may be greater than two troughs 84 or as few as one trough 84. Also, although troughs 84-1 and 84-2 are shown in the present embodiment having a particular size, shape, and orientation, it is to be understood that one or more of the size, shape, and orientation of troughs 84 may vary from what is shown in the present embodiment.

A plurality of receptacles 85 may be provided in areas of inner portion 80 outside of troughs 84. As will be discussed further below, receptacles 85 may be used to receive screws or other fasteners for securing one or more heat-spreaders to the bottom surface of top 35.

Outer portion 82 may extend peripherally along the rear, left side, and right side edges of inner portion 80. A rear section of outer portion 82 may be fixedly secured, for example, by an adhesive, mechanical fasteners, or other suitable means, to rear 39, a left section of outer portion 82 may be fixedly secured, for example, by an adhesive, mechanical fasteners, or other suitable means, to left side 41 and to left corner gusset 45, and a right section of outer portion 82 may be fixedly secured, for example, by an adhesive, mechanical fasteners, or other suitable means, to right side 43 and to right corner gusset 47.

Door 37, which is also shown separately in FIGS. 6A through 6C, may be a unitary, solid structure made of a molded composite material, such as a molded fiberglass composite or a molded carbon fiber composite. Door 37, which may be generally rectangular in overall shape, may be shaped to include an inner portion 90 and an outer portion 92. Inner portion 90 may be shaped to include a plurality of troughs 94-1 and 94-2, which may be used to receive phase-change material in the manner to be discussed below. Troughs 94-1 and 94-2 may be accessible from the rear of door 37. Although two troughs 94 are shown in the present embodiment, the number of troughs is not critical to the present invention; consequently, there may be greater than two troughs 94 or as few as one trough 94. Also, although troughs 94-1 and 94-2 are shown in the present embodiment having a particular size, shape, and orientation, it is to be understood that one or more of the size, shape, and orientation of troughs 94-1 and 94-2 may vary from what is shown in the present embodiment.

A plurality of receptacles 96 may be provided in areas of inner portion 90 outside of troughs 94. As will be discussed further below, receptacles 96 may be used to receive screws or other fasteners for securing one or more heat-spreaders to the rear surface of door 37. In addition, inner portion 90 may be shaped to include a plurality of recesses 98, 100 and 102, which may be used to receive brackets or other hardware for use in mounting phase-change material assemblies to the rear surface of door 37.

Door 37 may also be shaped to have one or more areas 104 of increased wall thickness proximate to troughs 94-1 and 94-2. For example, door 37 may transition from a wall thickness of 3 mm to a thickness of 6 mm in areas 104. Areas 104, which may be positioned proximate to the bottom of troughs 94 when shipper 13 is assembled and upright, may provide structural reinforcement to frame 31 against damage from an inclined shock, such as may occur when shipper 13, loaded with a pallet and payload, slides off the forks of a lift truck.

Outer portion 92, which may extend around the periphery of inner portion 90, may extend forwardly relative to inner portion 90 so as to define a cavity 110, which opens forwardly. Cavity 110 may be used to receive a plurality of vacuum insulation panels. Outer portion 92 may also be shaped to include, on its periphery, a recess 106 having a pair of openings 108-1 and 108-2. Recess 106 and openings 108-1 and 108-2 may be used to receive part of a door-latching mechanism. Outer portion 92 may further be shaped to include a pair of openings 109-1 and 109-2 and also a plurality of openings 111-1 through 111-4. As will be discussed further below, openings 109-1 and 109-2 and openings 111-1 through 111-4 may also be used to receive part of a door-latching mechanism.

Door 37 may comprise one or more thermal conduction breaks. For example, in the present embodiment, outer portion 92 of door 37 may be shaped to include one or more through openings, such openings serving as thermal conduction breaks to reduce the thermal conductivity of door 37 (since air has less thermal conductivity than the material used to make door 37). In contrast with many of the through openings of bottom 33, which may be formed only in the outer walls of border portions 58-2 through 58-4 (and which may not also be formed in the inner walls of border portions 58-2 through 58-4), the through openings of door 37 may pass entirely through outer portion 92 of door 37.

In the present embodiment, outer portion 92 of door 37 may comprise a top section 112, a bottom section 114, a left section 116 and a right section 118, one or more of which may include one or more such through openings serving as thermal conduction breaks. In the present embodiment, top section 112 may be shaped to include one or more through openings 120, bottom section 114 may be shaped to include one or more through openings 122, left section 116 may be shaped to include one or more through openings 124, and right section 118 may be shaped to include one or more through openings 126. The size, number and spacing of openings 120, 122, 124, and 126 may be similar to that disclosed in U.S. Pat. Application Publication No. US 2021/0070539 A1 or may be varied as desired.

Back 39, which is also shown separately in FIGS. 7A and 7B, may be a unitary, solid structure and may be made of a molded composite material, such as a molded fiberglass composite or a molded carbon fiber composite. Back 39, which may be generally rectangular in overall shape, may be shaped to include a pair of troughs 132-1 and 132-2 and a plurality of channels 134-1 through 134-3, with troughs 132 and channels 134 opening in opposite directions relative to one another. Each of troughs 132-1 and 132-2 may be used to receive phase-change material in the manner to be discussed below. Troughs 132-1 and 132-2 may be accessible from the front of back 39 and may be shaped to protrude rearward from a front surface of back 39. Although two troughs 132-1 and 132-2 are shown in the present embodiment, the number of troughs is not critical to the present invention; consequently, there may be greater than two troughs 132 or as few as one trough 132. Also, although troughs 132-1 and 132-2 are shown in the present embodiment having a particular size, shape, and orientation, it is to be understood that one or more of the size, shape, and orientation of troughs 132-1 and 132-2 may vary from what is shown in the present embodiment.

Channels 134-1 through 134-3, which may open rearwardly, may be shaped to extend vertically, with channels 134-1 and 134-2 extending along opposite sides of trough 132-1 and with channels 134-2 and 134-3 extending along opposite sides of trough 132-2. Channels 134-1 through 134-3 may be shaped to have one or more areas 138 of increased wall thickness. For example, channels 134-1 through 134-3 may transition from a wall thickness of 3 mm to a thickness of 6 mm in areas 138. Areas 138, which may be positioned proximate to the bottom of channels 134 when shipper 13 is assembled and upright, may provide structural reinforcement to frame 31 against damage from an inclined shock, such as may occur when shipper 13, loaded with a pallet and payload, slides off the forks of a lift truck.

A plurality of receptacles 140 and 141 may be provided in back 39 outside of troughs 132. As will be discussed further below, receptacles 140 and 141 may be used to receive screws or other fasteners for securing one or more heat-spreaders to the front surface of back 39. In addition, a plurality of recesses 142, 144 and 146 may also be provided in back 39. Recesses 142, 144, and 146 may be used to receive brackets or other hardware for use in mounting phase-change material assemblies to back 39.

Back 39 may be appropriately dimensioned to support a plurality of vacuum insulated panels positioned against its rearward surface.

Left side 41, which is also shown separately in FIGS. 8A and 8B, may be a unitary, solid structure and may be made of a molded composite material, such as a molded fiberglass composite or a molded carbon fiber composite. Left side 41, which may be generally rectangular in overall shape, may have a shape that is similar in some respects to back 39. Left side 41 may be shaped to include a pair of troughs 150-1 and 150-2 and a plurality of channels 152-1 through 152-3, with troughs 150 and channels 152 opening in opposite directions relative to one another. Each of troughs 150-1 and 150-2 may be used to receive phase-change material in the manner to be discussed below. Troughs 150-1 and 150-2 may be accessible from the inner side (i.e., right side) of left side 41 and may be shaped to protrude outwardly from the right surface of left side 41. Although two troughs 150 are shown in the present embodiment, the number of troughs is not critical to the present invention; consequently, there may be greater than two troughs 150 or as few as one trough 150. Also, although troughs 150-1 and 150-2 are shown in the present embodiment having a particular size, shape, and orientation, it is to be understood that one or more of the size, shape, and orientation of troughs 150-1 and 150-2 may vary from what is shown in the present embodiment.

Channels 152-1 through 152-3, which may open outwardly (i.e., leftward), may be shaped to extend vertically, with channels 152-1 and 152-2 extending along opposite sides of trough 150-1 and with channels 152-2 and 152-3 extending along opposite sides of trough 150-2. Channels 152-1 through 152-3 may be shaped to have one or more areas 156 of increased wall thickness. For example, channels 152-1 through 152-3 may transition from a wall thickness of 3 mm to a thickness of 6 mm in areas 156. Areas 156, which may be positioned proximate to the bottom of channels 152-1 through 152-3 when shipper 13 is assembled and upright, may provide structural reinforcement to frame 31 against damage from an inclined shock, such as may occur when shipper 13, loaded with a pallet and payload, slides off the forks of a lift truck.

Left side 41 may be appropriately dimensioned to support a plurality of vacuum insulated panels positioned against its outer surface.

A plurality of receptacles 160 and 161 may be provided in left side 41 outside of troughs 150-1 and 150-2. As will be discussed further below, receptacles 160 and 161 may be used to receive screws or other fasteners for securing one or more heat-spreaders to the right surface of left side 41. In addition, a plurality of recesses 162, 164 and 166 may also be provided in left side 41. Recesses 162, 164, and 166 may be used to receive brackets or other hardware for use in mounting phase-change material assemblies to left side 41.

Right side 43, which is also shown separately in FIGS. 9A and 9B, may be a unitary, solid structure and may be made of a molded composite material, such as a molded fiberglass composite or a molded carbon fiber composite. Right side 43, which may be generally rectangular in overall shape, may have a shape that is similar to left side 41. Right side 43 may be shaped to include a pair of troughs 170-1 and 170-2 and a plurality of channels 172-1 through 172-3, with troughs 170 and channels 172 opening in opposite directions relative to one another. Each of troughs 170-1 and 170-2 may be used to receive one or more trays containing one or more pouches of phase-change material. Troughs 170-1 and 170-2 may be accessible from the inner side (i.e., left side) of right side 43 and may be shaped to protrude outwardly from the left surface of right side 43. Although two troughs 170-1 and 170-2 are shown in the present embodiment, the number of troughs is not critical to the present invention; consequently, there may be greater than two troughs 170 or as few as one trough 170. Also, although troughs 170-1 and 170-2 are shown in the present embodiment having a particular size, shape, and orientation, it is to be understood that one or more of the size, shape, and orientation of troughs 170-1 and 170-2 may vary from what is shown in the present embodiment.

Channels 172-1 through 172-3, which may open outwardly (i.e., rightward), may be shaped to extend vertically, with channels 172-1 and 172-2 extending along opposite sides of trough 170-1 and with channels 172-2 and 172-3 extending along opposite sides of trough 170-2. Channels 172-1 through 172-3 may be shaped to have one or more areas 176 of increased wall thickness. For example, channels 172-1 through 172-3 may transition from a wall thickness of 3 mm to a thickness of 6 mm in areas 176. Areas 176, which may be positioned proximate to the bottom of channels 172-1 through 172-3 when shipper 13 is assembled and upright, may provide structural reinforcement to frame 31 against damage from an inclined shock, such as may occur when shipper 13, loaded with a pallet and payload, slides off the forks of a lift truck.

Right side 43 may be appropriately dimensioned to support a plurality of vacuum insulated panels positioned against its outer surface.

A plurality of receptacles 180 and 181 may be provided in right side 43 outside of troughs 170-1 and 170-2. As will be discussed further below, receptacles 180 and 181 may be used to receive screws or other fasteners for securing one or more heat-spreaders to the right surface of right side 43. In addition, a plurality of recesses 182, 184 and 186 may also be provided in right side 43. Recesses 182, 184, and 186 may be used to receive brackets or other hardware for use in mounting phase-change material assemblies to right side 43.

Left corner gusset 45, which is also shown separately in FIGS. 10A and 10B, may be a unitary, solid structure and may be made of a molded composite material, such as a molded fiberglass composite or a molded carbon fiber composite. Left corner gusset 45 may be shaped to include one or more through openings 190, openings 190 serving as thermal conduction breaks to reduce the thermal conductivity of left corner gusset 45. The size, number and spacing of openings 190 may be similar to that disclosed in U.S. Patent Application Publication No. US 2021/0070539 A1 or may be varied as desired.

Right corner gusset 47, which is also shown separately in FIGS. 11A and 11B, may be a unitary, solid structure and may be made of a molded composite material, such as a molded fiberglass composite or a molded carbon fiber composite. Right corner gusset 47 may be shaped to include one or more through openings 192, openings 192 serving as thermal conduction breaks to reduce the thermal conductivity of right corner gusset 47. The size, number and spacing of openings 192 may be similar to that disclosed in U.S. Patent Application Publication No. US 2021/0070539 A1 or may be varied as desired.

Right corner gusset 47 may also include an opening 194, which may receive, for example, a tracking device, a monitoring device, or the like. Right corner gusset 47 may also include a pair of openings 195-1 and 195-2 and may further include a plurality of openings 196-1 through 196-4. As will be discussed further below, openings 195-1 and 195-2 and openings 196-1 through 196-4 may be used to receive part of a door-latching mechanism.

In the present embodiment, top 35, back 39, left side 41, and right side 43 preferably do not include any thermal conduction breaks. Nevertheless, one or more of top 35, back 39, left side 41, and right side 43 could be modified to include one or more thermal conduction breaks.

Shipper 13 may further comprise a door hinge 200. Door hinge 200, which is also shown separately in FIG. 12 , may be a low-profile, high-strength hinge, such as a carbon-KEVLAR aramid hinge (Talon Technology, Brookvale, Australia) and may comprise a pair of carbon fiber composite wings 202-1 and 202-2 that are interconnected by a flexible Kevlar aramid bridge 203. Wing 202-1 may be fixedly secured by adhesive, mechanical fasteners or other suitable means to left corner gusset 45, and wing 202-2 may be fixedly secured by adhesive, mechanical fasteners, or other suitable means to door 37, thereby enabling door 37 to be moved between an open position and a closed position.

One of the reasons for using door hinge 200 is that it has a low profile, thereby minimizing the space that it occupies. This feature is particularly advantageous when door hinge 200 is exteriorly mounted as it does not significantly increase the overall dimensions of shipper 13. That being said, the present invention is not limited to using door hinge 200. For example, referring now to FIG. 13 , there is shown an alternative door hinge 220 that may be suitable for use with shipper 13, particularly when door hinge 220 is interiorly mounted so as to couple door 37 and left corner gusset 45. Door hinge 220, which may be a 3-way adjustable door hinge of the type commercially available as SUGATSUNE HES3D-120BL door hinge (Sugatsune America, Inc., Carson, CA) is constructed so that, when folded, the center portion folds into the recess between the two end portions. Preferably, a plurality of door hinges 220 may be used to couple door 37 to left corner gusset 45, the door hinges 220 preferably being spaced apart (evenly or unevenly) along the height of door 37, with one end of each hinge 220 preferably attached to the front surface of left corner gusset 45 and with the other end of each hinge 220 preferably attached to the rear surface of door 37.

Referring now to FIGS. 14A through 14C, shipper 13 may further comprise a door-latching mechanism 240. Door-latching mechanism 240 may be used to keep door 37 in a closed position and may be a conventional door-latching mechanism.

In the present embodiment, door-latching mechanism 240, which is also shown separately in FIGS. 14D through 14G, may comprise a rack-and-pinion/handle assembly 241. Assembly 241, in turn, may comprise a handle 243 and a rack-and-pinion mechanism 245.

Door-latching mechanism 240 may also comprise a pair of identical plate assemblies 251-1 and 251-2 that are coupled to opposite ends of rack-and-pinion mechanism 245. Each of plate assemblies 251-1 and 251-2 may comprise an extension arm 253, a locking finger 255, a guide plate 257, and a frame plate 259. Frame plates 259 may be fixed to right corner gusset 47 whereas the rest of door-latching mechanism 240 may be coupled to door 37. In particular, one of frame plates 259 may be fixed to right corner gusset 47 with screws 260-1 and 260-2 inserted through openings 261-1 and 261-2 of the frame plate 259 and through openings 196-1 and 196-2 of right corner gusset 47 so that an opening 262-1 in the frame plate 259 may be aligned with opening 195-1 of right corner gusset 47. In a similar manner, the other of frame plates 259 may be fixed to right corner gusset 47 with screws 260-3 and 260-4 inserted through openings 261-3 and 261-4 of the frame plate 259 and through openings 196-3 and 196-4 of right corner gusset 47 so that an opening 262-2 in the frame plate 259 may be aligned with opening 195-2 of right corner gusset 47. In addition, one of guide plates 257 may be fixed to the front surface of door 37 with screws 263-1 and 263-2 that are inserted through the guide plate 257 and through openings 111-1 and 111-2 of door 37 so that the locking finger 255 that is coupled to the guide plate 257 with screws 264-1 and 264-2 may extend through opening 109-1 of door 37. In a similar manner, the other of guide plates 257 may be fixed to the front surface of door 37 with screws 263-3 and 263-4 that are inserted through the guide plate 257 and through openings 111-3 and 111-4 of door 37 so that the locking finger 255 that is coupled to the guide plate 257 with screws 264-3 and 264-4 may extend through opening 109-2 of door 37.

Door latching mechanism 240 may operate by having the hooked end 265-1 of the upper locking finger 255 extend through opening 262-1 of the upper frame plates 259 and engage the rear surface of the upper frame plate 259 and by having the hooked end 265-2 of the lower locking finger 255 extend through opening 262-2 of the lower frame plate 259 and engage the rear surface of the lower frame plate 259. In use, handle 243 may be pulled out and rotated. The rotation of handle 243, in turn, may cause rack-and-pinion mechanism 245 to turn. As a result of the turning of rack-and-pinion mechanism 245, extension arms 253 and locking fingers 255 may translate up and down. The translation of locking fingers 255, in turn, may cause locking fingers 255 to be insertable into or removable through frame plates 259.

Referring back to FIG. 2C, shipper 13 may further comprise a plurality of insulating panels 281-1 through 281-24. Preferably, each of insulating panels 281-1 through 281-24 is a vacuum insulated panel (VIP), which VIP may be conventional in its construction and/or composition and may be as described in U.S. Patent Application Publication No. US 2021/0070539 A1. Panels 281-1 through 281-4 may be positioned in two layers of 2 VIPs per layer directly under and in contact with bottom 33. Panels 281-5 through 281-8 may be positioned in two layers of 2 VIPs per layer directly on top of and in contact with top 35. Panels 281-9 through 281-12 may be positioned in two layers of 2 VIPs per layer directly in front of and in contact with door 37. Panels 281-13 through 281-16 may be positioned in two layers of 2 VIPs per layer directly behind and in contact with back 39. Panels 281-17 through 281-20 may be positioned in two layers of 2 VIPs per layer directly exterior to and in contact with left side 41. Panels 281-21 through 281-24 may be positioned in two layers of 2 VIPs per layer directly exterior to and in contact with right side 43. If desired, some or all of panels 281-1 through 281-24 may be held in place on frame 31 using plastic wrap or the like (not shown).

In the present embodiment, the four VIPs on each of the six sides of frame 31 may come in two different sizes, a first size having a comparatively larger footprint and a second size having a comparatively smaller footprint. (The thicknesses of all four VIPs may be the same, and the thickness of an individual VIP may be, for example, 0.75-1.0 inch.) Each layer of the two layers of VIPs may comprise a VIP having a comparatively larger footprint and a VIP having a comparatively smaller footprint; however, the arrangement of the two VIPs in the two layers may be the opposite of one another. In other words, if one of the layers includes a VIP having a comparatively smaller footprint to the left of a VIP having a comparatively larger footprint, the other layer may include a VIP having a comparatively larger footprint to the left of a VIP having a comparatively smaller footprint. One reason for such an arrangement is to ensure that the seams between the VIPs of the two layers are not aligned with one another. By not aligning the seams with one another, a longer path is needed for heat to flow through the two layers of VIPs. A longer path typically results in improved thermal performance.

In addition, although not shown, a protective layer may be interposed between each foursome of panels 281 and the portion of frame 31 that is associated with said foursome of panels 281. The protective layer, which may comprise, for example, a TYVEK® flashspun nonwoven sheet of high density polyethylene fibers (DuPont de Nemours, Inc., Wilmington, DE), may completely cover the surfaces of the foursome of panels 281 that would otherwise be in contact with frame 31. Also, if desired, some or all of panels 281-1 through 281-24 may be held in place on frame 31 using plastic wrap or the like (not shown).

Referring back now to FIGS. 1A through 1C and FIGS. 2A through 2C, shipper 13 may further comprise an outer shell. The outer shell, in turn, may comprise a first shell portion 291 and a second shell portion 293. First shell portion 291, which is also shown separately in FIGS. 15A and 15B, may be shaped to include a front 295-1 dimensioned to cover the exterior of door 37 (as well as to cover panels 281-9 through 281-12), a top 295-2 dimensioned to cover the top of door 37, a bottom 295-3 dimensioned to cover the bottom of door 37, a left side 295-4 dimensioned to cover at least a portion of the left side of door 37, a right side 295-5 dimensioned to cover at least a portion of the right side of door 37, and an open rear. A cutout 297 may be provided in left side 295-4 to accommodate wing 202-2 of door hinge 200, and a cutout 299 may be provided in right side 295-5 to accommodate a portion of door-latching mechanism 240. First shell portion 291 may be fixedly secured to door 37 by mechanical fasteners (e.g., screws), adhesive or other suitable means. A rail or bracket 300 may be used to secure the bottom of shell portion 291 to door 37. Openings (not shown) may be provided in first shell portion 291 through which such mechanical fasteners may be inserted.

Second shell portion 293, which is also shown separately in FIGS. 16A and 16B, may be shaped to include a front 303-1, a back 303-2, a top 303-3, a left side 303-4, a right side 303-5, and an open bottom. Second shell portion 293 may be appropriately dimensioned to cover nearly all of the exterior surfaces of top 35, back 39, left side 41, right side 43, left corner gusset 45, and right corner gusset 47. Second shell portion 293 may be fixedly secured to one or more of the exterior surfaces of bottom 33, top 35, back 39, left side 41 and right side 43 by mechanical fasteners (e.g., screws), adhesive or the like. Rails or brackets 301-1 through 301-3 may be used to secure the bottom of second shell portion 293 to bottom 33. Openings (not shown) may be provided in second shell portion 293 through which such mechanical fasteners may be inserted.

Each of first shell portion 291 and second shell portion 293 may be a unitary, solid structure made of one or more materials possessing low thermal conductivity and good mechanical strength. Examples of particularly suitable materials may comprise composite materials, such as fiberglass composite and carbon fiber composite. Such materials may be molded to form each of first shell portion 291 and second shell portion 293. In one embodiment, the composite material used to make first shell portion 291 and second shell portion 293 may be a multilayer material comprising a gel coat (e.g., POLYCOR 944W005 white isophthalic gel coat, Polynt Composites USA, Inc., Carpentersville, IL) of about 0.508-0.558 mm in thickness, a 0.75 oz. chop strand mat (e.g., JUSHI P04 powder chopped strand mat, Jushi USA, Irwindale, CA) of about 0.483 mm in thickness, a 1708 biaxial glass layer (e.g., VECTORPLY E-BXM 1708, Vectorply Corporation, Phenix City, AL) of about 1.2 mm in thickness, and a carbon fiber 1.5 oz. mat (e.g., TORAY T700S standard modulus carbon fiber, Toray Composite Materials America, Inc., Tacoma, WA) of about 0.965 mm in thickness.

As seen best in FIG. 1B, shipper 13 may further comprise a lower panel 311. Lower panel 311, which may be made of wood, plastic, composite material, or another suitable material, may be fixedly secured to the bottom surface of bottom 33 by mechanical fasteners 318. Lower panel 311 may be shaped to comprise a plurality of support feet 317. Support feet 317 may serve to elevate shipper 13 so that shipper 13 may be moved with a forklift or the like. In addition, support feet 317 may be made of a suitable material to provide some shock absorbance. In the present embodiment, five support feet 317 are shown in a specific pattern; however, a greater or lesser number of support feet 317 may be used, and support feet 317 may be arranged in a pattern that differs from that shown.

Shipping system 11 may further comprise one or more insulating strips (not shown). These insulating strips, which may be made of expanded polystyrene or the like, may be appropriately dimensioned so that they may be positioned around one or more of front border portion 58-1, rear border portion 58-2, left side border portion 58-3, and right side border portion 58-4 of bottom 33.

Shipper 13 may further comprise a plurality of PCM assemblies and a plurality of heat-spreader assemblies. For example, a heat-spreader assembly may be coupled to the inside surface of each of bottom 33, top 35, door 37, back 39, left side 41 and right side 43, and one or more PCM assemblies may be positioned between each of bottom 33, top 35, door 37, back 39, left side 41, and right side 43 and its respective heat-spreader assembly. In at least one embodiment, there may be a number of different types of PCM assemblies, and there may be a number of different types of heat-spreader assemblies. For instance, door 37 may be equipped with two different types of PCM assemblies, namely, a first type of PCM assembly and a second type of PCM assembly, and door 37 may also be equipped with a first type of heat-spreader assembly. Back 39 may be equipped with the same two types of PCM assemblies that are associated with door 37, and back 39 may also be equipped with the same type of heat-spreader assembly that is associated with door 37. Accordingly, unless specified otherwise, any discussion or depiction in the present application of PCM assemblies and a heat-spreader assembly in the context of door 37 is equally applicable to back 39. In addition, left side 41 may be equipped with two additional types of PCM assemblies, namely, a third type of PCM assembly and a fourth type of PCM assembly, and left side 41 may also be equipped with an additional type of heat-spreader assembly, namely, a second type of heat-spreader assembly. Right side 43 may be equipped with the same two types of PCM assemblies associated with left side 41, and right side 43 may also be equipped with the same type of heat-spreader assembly associated with left side 41. Accordingly, unless specified otherwise, any discussion or depiction in the present application of PCM assemblies and a heat-spreader assembly provided in the context of left side 41 is equally applicable to right side 43. Additionally, top 35 may be equipped with an additional type of PCM assembly, namely, a fifth type of PCM assembly, and top 35 may also be equipped with an additional two types of heat-spreader assembly, namely, a third type of heat-spreader assembly and a fourth type of heat-spreader assembly. In addition, bottom 33 may be equipped with an additional type of PCM assembly, namely, a sixth type of PCM assembly, and bottom 33 may also be equipped with an additional two types of heat-spreader assembly, namely, a fifth type of heat-spreader assembly and a sixth type of heat-spreader assembly.

More specifically, various views of shipper 13 are shown in FIGS. 17A through 17E, with certain components not being shown to reveal details of the PCM assemblies and/or heat-spreader assemblies of shipper 13. As can be seen, door 37 may be equipped with two different types of PCM assemblies, which may be an upper PCM assembly and a lower PCM assembly. More specifically, in the present embodiment, door 37 may be equipped with two identical upper PCM assemblies 351-1 and 351-2 and with two identical lower PCM assemblies 353-1 and 353-2. Back 39 may be equipped with two identical upper PCM assemblies 352-1 and 352-2 and with two identical lower PCM assemblies 354-1 and 354-2. Upper PCM assemblies 352-1 and 352-2 for back 39 may be identical to upper PCM assemblies 351-1 and 351-2 for door 37, and lower PCM assemblies 354-1 and 354-2 for back 39 may be identical to lower PCM assemblies 353-1 and 353-2 for door 37.

Left side 41 may be equipped with an additional two different types of PCM assemblies, which may be an upper PCM assembly and a lower PCM assembly. More specifically, in the present embodiment, left side 41 may be equipped with two identical upper PCM assemblies 355-1 and 355-2 and with two identical lower PCM assemblies 357-1 and 357-2. Although not shown, right side 43 may be equipped with the same array of PCM assemblies as left side 41.

Top 35 may be equipped with an additional type of PCM assembly. More specifically, in the present embodiment, top 35 may be equipped with four identical PCM assemblies 359-1 through 359-4. In addition, bottom 33 may be equipped with an additional type of PCM assembly. More specifically, in the present embodiment, bottom 33 may be equipped with four identical PCM assemblies 361-1 through 361-4.

PCM assemblies 351-1, 351-2, 352-1, 352-2, 353-1, 353-2, 354-1, 354-2, 355-1, 355-2, 357-1, 357-2, 359-1, 359-2, 359-3, 359-4, 361-1, 361-2, 361-3, and 361-4 may be similar or identical to PCM assemblies 351-1, 351-2, 352-1, 352-2, 353-1, 353-2, 354-1, 354-2, 355-1, 355-2, 357-1, 357-2, 359-1, 359-2, 359-3, 359-4, 361-1, 361-2, 361-3, and 361-4, respectively, of U.S. Patent Application Publication No. US 2021/0070539 A1 and may be mounted in a similar or identical fashion using, in some cases, a mounting rod 391. Notwithstanding the above, PCM assemblies 351-1, 351-2, 352-1, 352-2, 353-1, 353-2, 354-1, 354-2, 355-1, 355-2, 357-1, 357-2, 359-1, 359-2, 359-3, 359-4, 361-1, 361-2, 361-3, and 361-4 are not limited to the structures disclosed in U.S. Patent Application Publication No. US 2021/0070539 A1 and could be replaced with other types of phase-change material assemblies or could be omitted or consolidated in some fashion.

Each of PCM assemblies 351-1, 351-2, 352-1, 352-2, 353-1, 353-2, 354-1, 354-2, 355-1, 355-2, 357-1, 357-2, 359-1, 359-2, 359-3, 359-4, 361-1, 361-2, 361-3, and 361-4 may contain the same type of phase-change material. Alternatively, some of PCM assemblies 351-1, 351-2, 352-1, 352-2, 353-1, 353-2, 354-1, 354-2, 355-1, 355-2, 357-1, 357-2, 359-1, 359-2, 359-3, 359-4, 361-1, 361-2, 361-3, and 361-4 may contain a first type of phase-change material, and other of PCM assemblies 351-1, 351-2, 352-1, 352-2, 353-1, 353-2, 354-1, 354-2, 355-1, 355-2, 357-1, 357-2, 359-1, 359-2, 359-3, 359-4, 361-1, 361-2, 361-3, and 361-4 may contain a second type of phase-change material. Alternatively, some or all of PCM assemblies 351-1, 351-2, 352-1, 352-2, 353-1, 353-2, 354-1, 354-2, 355-1, 355-2, 357-1, 357-2, 359-1, 359-2, 359-3, 359-4, 361-1, 361-2, 361-3, and 361-4 may contain two or more different types of phase-change materials, for example, with a first type of phase-change material in some pouches or pockets and a second type of phase-change material in other pouches or pockets of the same PCM assembly. Further details of the types of phase-change materials that may be used in shipper 13 may be found in U.S. Patent Application Publication No. US 2021/0070539 A1.

Referring now to FIGS. 1C, 2A, 17C, 17D, and 17E, there is shown, amongst other things, one embodiment of a heat-spreader assembly that is associated with door 37, the heat-spreader assembly being represented generally by reference numeral 451. Heat-spreader assembly 451 may comprise a pair of heat-conductive panels 453 and 455, each of which may be an aluminum sheet or other suitable material. In the present embodiment, each of heat-conductive panels 453 and 455 may be an aluminum sheet having a thickness of approximately 1/16 inch, with heat-conductive panel 453 being dimensioned to cover approximately the upper halves of trough 94-1 and 94-2 and with heat-conductive panel 455 being dimensioned to cover approximately the lower halves of troughs 94-1 and 94-2. Heat-conductive panels 453 and 455 may be coupled together with a piano hinge 457 or other suitable hinge.

A plurality of fasteners 459, which may be, for example, nine permanent screws (for example, three screws secured to the lower half of rib 405, three screws secured to the lower half of rib 407, and three screws secured to the lower half of rib 409), may be used to permanently secure panel 455 to door 37. Panel 453 may be removably secured to door 37 with a fastener 461, which may be, for example, a quarter-turn screw secured in a receptacle 462 provided at the top of rib 409, and a pair of finger pull slam latches 463-1 and 463-2 used to releasably engage a pair of keepers 465-1 and 465-2, respectively, on the upper portions of ribs 405 and 407, respectively.

PCM assemblies 351-1, 351-2, 353-1 and 353-2 may be securely retained between door 37 and heat-spreader assembly 451. To remove one or more of PCM assemblies 351-1, 351-2, 353-1 and 353-2 (for example, to thermally recondition the PCM assembly independently of the remainder of the shipper, to replace a worn or damaged PCM assembly, to reconfigure the shipper to include a PCM assembly having a different type of phase change material (e.g., for maintaining the payload within a different target temperature range), etc.), one may first loosen or remove fastener 461, using a screwdriver or similar tool, and then may manually detach latches 463-1 and 463-2 from keepers 465-1 and 465-2, respectively. Then, one may pivot panel 453 away from door 37 (while keeping panel 455 secured to door 37), thereby exposing upper PCM assemblies 351-1 and 351-2. One or both of upper PCM assemblies 351-1 and/or 351-2 may be removed by lifting the PCM assembly out of its trough 94. (If PCM assembly 351-1 or 351-2 is secured to door 37 with hook/loop fasteners, such fasteners are detached prior to lifting the PCM assembly out of its trough 94.) Once an upper PCM assembly 351 has been removed, the lower PCM assembly 353 situated therebeneath may be exposed and may be removed.

To install PCM assemblies 351-1, 351-2, 353-1 and 353-2 on door 37, panel 453 may be pivoted away from door 37 in the manner described above, and lower PCM assemblies 353-1 and 353-2 may then be lowered into the spaces between the bottom portions of troughs 94-1 and 94-2 and panel 455. Then, upper PCM assemblies 351-1 and 351-2 may be inserted into the upper portions of troughs 94-1 and 94-2 using mounting rods 391. Panel 453 may then be reattached to door 37, for example, by pivoting panel 453 towards door 37 and by manually operating finger pull slam latches 463-1 and 463-2 so that they engage keepers 465-1 and 465-2, respectively, and then by screwing fastener 461 to door 37.

Upper PCM assemblies 352-1 and 352-2 and lower PCM assemblies 354-1 and 354-2, all of which are associated with back 39, may be identical to upper PCM assemblies 351-1 and 351-2 and lower PCM assemblies 353-1 and 353-2, respectively, and may be mounted or otherwise coupled to back 39 in the same manner described above for door 37. Similarly, heat-spreader assembly 471, which is associated with back 39, may be identical to heat-spreader assembly 451 and may be secured to back 39 in the same manner that heat-spreader assembly 451 may be secured to door 37.

Heat-spreader assembly 481, which is associated with left side 41, may be similar to heat-spreader assembly 451, the respective heat-spreader assemblies differing only with regard to their relative widths (the thicknesses of the respective heat-spreader assemblies being the same). Heat-spreader assembly 481 may be secured to left side 41 in the same manner that heat-spreader assembly 451 may be secured to door 37.

Referring now to FIG. 17F, there is shown a view illustrating the way in which PCM assembly 359-3 may be mounted on top 35 and may be covered by heat-spreader assembly 492-1. (PCM assembly 359-4 (not shown in FIG. 17F) may also be covered by heat-spreader assembly 492-1, and PCM assemblies 359-1 and 359-2 (not shown in FIG. 17F) may be covered by heat-spreader assembly 492-2.)

PCM assembly 359-3 may be held against top 35 by one or more straps 503 each having one end fixed to top 35 near right side 43 and another end with a strip of hook fasteners of the complementary hook-and-loop variety (e.g., VELCRO® hook-and-loop fasteners) that may mate with PCM assembly 359-3. PCM assemblies 359-1, 359-2 and 359-4 may be held against top 35 in a similar fashion.

Heat-spreader assemblies 492-1 and 492-2 may be similar to heat-spreader assembly 451, except that heat-spreader assemblies 492-1 and 492-2 do not have a structure corresponding to panel 455. Instead, heat-spreader assembly 492-1 may comprise a panel 509-1 that may be hingedly connected to top 35 proximate to right side 43, and heat-spreader assembly 492-2 may comprise a panel 509-2 that may be hingedly connected to top 35 proximate to left side 41. In a manner similar to that disclosed in U.S. Patent Application Publication No. US 2021/0070539 A1, each of heat-spreader assemblies 492-1 and 492-2 may be secured to top 35 approximately midway between left side 41 and right side 43 with a combination of quarter-turn screws and a pair of finger pull slam latches used to releasably engage keepers.

Referring now to FIGS. 18A through 18D, there are shown various views illustrating the way in which PCM assemblies 361-1 through 361-4 may be mounted on bottom 33 and may be covered by a pair of heat-spreader assemblies 531-1 and 531-2. More specifically, as seen best in FIG. 18B, PCM assemblies 361-1 through 361-4 may be inserted into troughs 56-1 through 56-4, respectively, of bottom 33. (Because PCM assemblies 361 sit within troughs 56 of bottom 33, there is no need to strap, or otherwise to secure, PCM assemblies 361 in place.) Heat-spreader assemblies 531-1 and 531-2 may be similar to heat-spreader assemblies 492-1 and 492-2, respectively, except that (i) heat-spreader assemblies 531-1 and 531-2 may comprise panels 535-1 and 535-2 having an increased thickness compared to panels 509-1 and 509-2 (e.g., ¼ inch thickness for panels 535-1 and 535-2 vs. 1/16 inch thickness for panels 509-1 and 509-2); (ii) heat-spreader assemblies 531-1 and 531-2 may not include structures like quarter-turn screws 511 and finger pull slam latches 513 for securing panels 535-1 and 535-2 to bottom 33, heat-spreader assemblies 531-1 and 535-2 instead relying on gravity, as well as on the weight of any payload thereon; and (iii) heat-spreader assemblies 531-1 and 531-2 may include air cylinders 537-1 and 537-2 (not shown in FIG. 18B) to facilitate the lifting of panels 535-1 and 535-2.

Heat-spreader panel 535-1 may be hingedly connected to bottom 33 proximate to right side 43, and heat-spreader panel 535-2 may be hingedly connected to bottom 33 proximate to left side 41.

Referring now to FIGS. 19A through 19F, shipper 13 may further comprise a pair of identical payload retaining members 551-1 and 551-2, which may be used to help keep a payload P stationary within shipper 13. Each of payload retaining members 551-1 and 551-2 may comprise a strap 553 that may be fixed at one end to frame 31 along its back edge. A buckle 555 may be attached to the free end of each strap 553. A pair of identical receivers 557-1 and 557-2 may be mounted in recesses 59-1 and 59-2, respectively, at the front end of bottom 33, receivers 557 being adapted to mate with buckles 555. (Cutouts may be provided in panels 535-1 and 535-2 to provide access to receivers 557-1 and 557-2.) Straps 553 may be appropriately dimensioned to be drawn over payload P, with buckles 555 mating with receivers 557.

Referring back now to FIG. 1C, shipper 13 may further include a kickstand (shown simplistically in FIG. 1C as kickstand 561). Kickstand 561, which may be used to maintain door 37 in an open position, may be pivotally mounted on the inner surface of door 37 proximate to its bottom edge.

As noted above, shipping system 11 may include, in addition to shipper 13, a door plug assembly 15. As will become apparent from the discussion below, door plug assembly 15 may provide additional thermal protection at the end of space 29 that is proximate to door 37. In fact, door plug assembly 15 may provide some degree of thermal protection to a payload within space 29, even when door 37 is open for a brief period of time. In addition, door plug assembly 15 may also serve to mount a data logger used, for example, to monitor the temperature within shipper 13.

Referring now to FIGS. 20A and 20B, there are shown enlarged perspective and exploded perspective views, respectively, of door plug assembly 15.

Door plug assembly 15, which may be appropriately dimensioned to be inserted, preferably snugly, into the open end of shipper 13 just inside of door 37, may comprise a plug 603, a front backing sheet 605, and a rear backing sheet 607.

Plug 603, which is also shown separately in FIGS. 21A through 21C, may be a unitary (i.e., one-piece) structure comprising a flexible piece of thermally insulating material. Materials suitable for use in making plug 603 may include, for example, expanded polystyrene foams, polyurethane foams, and/or expanded polypropylene foams. A particularly preferred material may be an open cell urethane foam having a density of 1.50±0.15 lb/ft³. Even though, in the present embodiment, plug 603 is a one-piece monolayer structure, it is to be understood that plug 603 may comprise multiple layers of similar or different materials and/or may be made by joining together a plurality of pieces. Plug 603 may be dimensioned to fit snugly within the open end of space 29, preferably just inside of door 37, in such a way as to substantially close the open end of space 29.

Plug 603 may be a generally rectangular member and may be shaped to include a front 611, a back 613, a bottom 615, a top 617, a left side 619, and a right side 621. Plug 603 may further be shaped to include a transverse opening 623. Transverse opening 623, which may be generally rectangular in shape, may be approximately equidistant from left side 619 and right side 621 and may be closer to top 617 than to bottom 615. As will be discussed further below, transverse opening 623 may be used to receive a data logger holder. Plug 603 may additionally be shaped to include transverse openings 625 and 627. Transverse openings 625 and 627 may be positioned on opposite sides of transverse opening 623, and each of transverse openings 625 and 627 may be generally rectangular and similar in size to transverse opening 623, except that each of transverse openings 625 and 627 may include a depression 628 along its lower edge. As will be discussed further below, each of transverse openings 625 and 627 may be used to receive a handle insert. Plug 603 may also be shaped to include two recesses 629 and 631 along its bottom edge. Recesses 629 and 631, which may be generally rectangular in shape, may be dimensioned so that buckles 555 of payload retaining members 551-1 and 551-2 may access receivers 557-1 and 557-2 on the floor of shipper 13.

Plug 603 is preferably dimensioned so that when door plug assembly 15 is mounted within shipper 13, each of bottom 615, top 617, left side 619 and right side 621 engages the corresponding edge of space 29. Without wishing to be limited to any particular dimensions, illustrative dimensions for plug 603 may include the following: a length from bottom 615 to top 617 of approximately 51 in; a width from left side 619 to right side 621 of approximately 41.5 in; a thickness from front 611 to back 613 of approximately 2 in; a length of approximately 8.25 in and a width of approximately 4.25 in for transverse opening 623; a length of approximately 2.5 in and a width of approximately 0.375 in for each of depressions 628 of transverse openings 625 and 627; a spacing of approximately 3.75 in between transverse opening 623 and each of transverse openings 625 and 627; a length (in the direction from bottom 615 towards top 617) of approximately 5.5 in for each of recesses 629 and 631; a width (in the direction from left side 619 to right side 621) of approximately 8 in for each of recesses 629 and 631; and a spacing of approximately 12.5 in between recesses 629 and 631.

Front backing sheet 605, which is shown separately in FIGS. 22A and 22B, may be a unitary (i.e., one-piece) structure comprising a rigid or stiff sheet of material, such as a sheet of corrugated polypropylene. (Even though, in the present embodiment, front backing sheet 605 is a one-piece monolayer structure, it is to be understood that front backing sheet 605 may comprise multiple layers of similar or different materials and/or may be made by joining together a plurality of pieces.) Front backing sheet 605 may have a footprint that is slightly smaller than that of plug 603. Front backing sheet 605 may be generally centered relative to front 611 of plug 603 and may be secured thereto.

Front backing sheet 605 may be a generally rectangular member and may be shaped to include a front 651, a back 653, a bottom 655, a top 657, a left side 659, and a right side 661. Front backing sheet 605 may further be shaped to include a transverse opening 663, which may be generally rectangular in shape and which may be aligned with transverse opening 623 of plug 603. Front backing sheet 605 may also be shaped to include a pair of integral, pop-out handles 665 and 667, which may be aligned with transverse openings 625 and 627, respectively. Front backing sheet 605 may further be shaped to include a cut-away portion 669 along a lower portion of right side 661. Cut-away portion 669, which may be generally rectangular in shape, may be used to receive a kickstand mounted on the inner surface of door 37 (i.e., to allow kickstand 561 to be pressed against the more compressible plug 603 to ensure that door 37 may close). Front 651 of front backing sheet 605 may provide a suitable surface for branding and/or instructions for use of door plug assembly 15.

Without wishing to be limited to any particular dimensions, illustrative dimensions for front backing sheet 605 may include the following: a length from bottom 655 to top 657 of approximately 48 in; a width from left side 659 to right side 661 of approximately 39.5 in; a thickness from front 651 to back 653 of approximately 0.157 in; a length of approximately 4.625 in and a width of approximately 2.75 in for transverse opening 663; a length of approximately 6.3 in and a width of approximately 3.8 in for each of pop-out handles 665 and 667; a spacing of approximately 6.5 in between transverse opening 663 and each of pop-out handles 665 and 667; a length (in the direction from bottom 655 towards top 657) of approximately 11.5 in for cutaway portion 669.

Rear backing sheet 607, which is shown separately in FIGS. 23A and 23B, may be a unitary (i.e., one-piece) structure comprising a rigid or stiff sheet of material, such as a sheet of corrugated polypropylene. (Even though, in the present embodiment, rear backing sheet 607 is a one-piece monolayer structure, it is to be understood that rear backing sheet 607 may comprise multiple layers of similar or different materials and/or may be made by joining together a plurality of pieces.) Rear backing sheet 607 may have a footprint that is slightly smaller than that of plug 603. Rear backing sheet 607 may be generally centered relative to back 613 of plug 603 and may be secured thereto.

Rear backing sheet 607 may be a generally rectangular member and may be shaped to include a front 671, a back 673, a bottom 675, a top 677, a left side 679, and a right side 681. Rear backing sheet 607 may further be shaped to include a pair of transverse openings 683-1 and 683-2, both of which may be aligned with transverse opening 623 of plug 603. Transverse openings 683-1 and 683-2 may be generally circular in shape. One or both of transverse openings 683-1 and 683-2 may be used to pass wiring from a data logger that is mounted within plug 603 to an interior location within space 29. Rear backing sheet 607 may also be shaped to include a pair of recesses 685-1 and 685-2 along its bottom edge. Recesses 685-1 and 685-2, which may be generally rectangular in shape, may be aligned with recesses 629 and 631 of plug 603 and may be dimensioned so that buckles 555 of payload retaining members 551-1 and 551-2 may access receivers 557-1 and 557-2 on the floor of shipper 13.

Without wishing to be limited to any particular dimensions, illustrative dimensions for rear backing sheet 607 may include the following: a length from bottom 675 to top 677 of approximately 48 in; a width from left side 679 to right side 681 of approximately 39.5 in; a thickness from front 671 to back 673 of approximately 0.156 in; a diameter for each of transverse openings 683-1 and 683-2 of approximately 0.625 in; a spacing between transverse openings 683-1 and 683-2 of approximately 3.5 in; a distance of approximately 18 in from transverse opening 683-1 to left side 679 and a distance of approximately 18 in from transverse opening 683-2 to right side 681; a length (in the direction from left side 679 to right side 681) of approximately 8 in and a width (in the direction of bottom 675 to top 677) of approximately 4 in for each of recesses 685-1 and 685-2; and a spacing of approximately 12.5 in between recesses 685-1 and 685-2.

Front backing sheet 605 and rear backing sheet 607 may be removably or permanently secured to the front and rear faces, respectively, of plug 603 using any suitable chemical and/or mechanical means and may serve to provide stiffening support to plug 603, which otherwise may be incapable of self-support or which may exhibit poor self-support.

Door plug assembly 15 may further comprise a pair of handle inserts 701-1 and 701-2. Handle inserts 701-1 and 701-2 may be identical to one another; thus, the discussion below of handle insert 701-1 may be equally applicable to handle insert 701-2. Handle insert 701-1, which is also shown separately in FIGS. 24A through 24C, may be a unitary (i.e., one-piece) structure comprising a piece of thermally insulating material. Materials suitable for use in making handle insert 701-1 may include, for example, expanded polystyrene foams, polyurethane foams, and/or expanded polypropylene foams. A particularly preferred material may be an open cell urethane foam having a density of 1.50±0.15 lb/ft³. Even though, in the present embodiment, handle insert 701-1 is a one-piece monolayer structure, it is to be understood that handle insert 701-1 may comprise multiple layers of similar or different materials and/or may be made by joining together a plurality of pieces.

Handle insert 701-1, which may be dimensioned to fit snugly within opening 625 of plug 603, may be a generally rectangular member shaped to include a front 703, a back 705, a bottom 709, a top 711, a left side 713, and a right side 715. Bottom 709 may be shaped to include a projection 716 that may matingly engage depression 628 of opening 625. Handle insert 701-1 may further be shaped to include a transverse opening 717. Transverse opening 717, which may be substantially centered, may be generally rectangular in shape and may be dimensioned so that a user may insert a portion of his/her hand thereinto. By using handle insert 701-1 in this manner to form a handle, door plug assembly 15 may be transported, installed in shipper 13 and/or removed from shipper 13.

Handle inserts 701-1 and 701-2 may be removably or permanently secured within transverse openings 625 and 627, respectively, of plug 603 and may be so secured using any suitable chemical and/or mechanical means.

Without wishing to be limited to any particular dimensions, illustrative dimensions for handle insert 701-1 may include the following: a width from bottom 709 (excluding projection 716) to top 711 of approximately 4.281 in; a length from left side 713 to right side 715 of approximately 8.281 in; a thickness from front 703 to back 705 of approximately 2 in; a length (in the direction from left side 713 to right side 715) of approximately 5.5 in and a width of approximately 3 in (in the direction from bottom 709 to top 711) for transverse opening 717; a width (in the direction from bottom 709 top 711) of approximately 0.64 in and a length (in the direction from left side 713 to right side 715) of approximately 1.25 in for projection 716; and a spacing of approximately 2.891 in from left side 713 to projection 716.

Door plug assembly 15 may further comprise a pair of handle insert plugs 731-1 and 731-2. Handle insert plugs 731-1 and 731-2 may be identical to one another; thus, the discussion below of handle insert plug 731-1 may be equally applicable to handle insert plug 731-2. Handle insert plug 731-1, which is also shown separately in FIGS. 25A through 25C, may be a unitary (i.e., one-piece) structure comprising a piece of thermally insulating material. Materials suitable for use in making handle insert plug 731-1 may include, for example, expanded polystyrene foams, polyurethane foams, and/or expanded polypropylene foams. A particularly preferred material may be an open cell urethane foam having a density of 1.50±0.15 lb/ft³. Even though, in the present embodiment, handle insert plug 731-1 is a one-piece monolayer structure, it is to be understood that handle insert plug 731-1 may comprise multiple layers of similar or different materials and/or may be made by joining together a plurality of pieces.

Handle insert plug 731-1, which may be dimensioned to fit snugly within a rear portion of transverse opening 717 of handle insert 701-1, may be a generally rectangular member shaped to include a front 733, a back 735, a bottom 739, a top 741, a left side 743, and a right side 745. Bottom 739 may be shaped to include a projection 746 that may matingly engage the inside of projection 716 of handle insert 701-1.

Handle insert plugs 731-1 and 731-2 may function to substantially close the rear of openings 717 in handle inserts 701-1 and 701-2, thereby minimizing thermal losses through openings 717. Handle insert plugs 731-1 and 731-2 may be removably or permanently secured within handle inserts 701-1 and 701-2, respectively, and may be so secured using any suitable chemical and/or mechanical means.

Without wishing to be limited to any particular dimensions, illustrative dimensions for handle insert plug 731-1 may include the following: a width from bottom 739 (excluding projection 746) to top 741 of approximately 3 in; a length from left side 743 to right side 745 of approximately 5.5 in; a thickness from front 733 to back 735 of approximately 0.5 in; a length (in the direction from left side 743 to right side 745) of approximately 1.25 in and a width of approximately 0.625 in (in the direction from bottom 739 to top 741) for projection 746; and a spacing of 2.125 in from left side 743 to projection 746.

Door plug assembly 15 may further comprise a data logger holder 771. Data logger holder 771, which is also shown separately in FIGS. 26A through 26C, may be a unitary (i.e., one-piece) structure comprising a piece of thermally insulating material. Materials suitable for use in making data logger holder 771 may include, for example, expanded polystyrene foams, polyurethane foams, and/or expanded polypropylene foams. A particularly preferred material may be an open cell urethane foam having a density of 1.50±0.15 lb/ft³. Even though, in the present embodiment, data logger holder 771 is a one-piece monolayer structure, it is to be understood that data logger holder 771 may comprise multiple layers of similar or different materials and/or may be made by joining together a plurality of pieces.

Data logger holder 771, which may be dimensioned to fit snugly within transverse opening 623 of plug 603, may be a generally rectangular member shaped to include a front 773, a back 775, a bottom 779, a top 781, a left side 783, and a right side 785. Data logger holder 771 may further be shaped to include a transverse opening 777. Transverse opening 777, which may be substantially centered, may be generally rectangular in shape and may be dimensioned to matingly receive a data logger. Through slits 787-1 and 787-2 may be formed in data logger holder 771 and may extend a portion of the distance from transverse opening 777 towards left side 783 and towards right side 785, respectively.

Data logger holder 771 may be removably or permanently secured within transverse opening 623 of plug 603 and may be so secured using any suitable chemical and/or mechanical means.

Without wishing to be limited to any particular dimensions, illustrative dimensions for data logger holder 771 may include the following: a width from bottom 779 to top 781 of approximately 4.281 in; a length from left side 783 to right side 785 of approximately 8.281 in; a thickness from front 773 to back 775 of approximately 2 in; a length (in the direction from left side 773 to right side 775) of approximately 4 in and a width of approximately 1.875 in (in the direction from bottom 779 to top 781) for transverse opening 777; a spacing of approximately 2.141 in from left side 773 to transverse opening 777; and a length of approximately 2 in for each of through slits 779-1 and 779-2.

Door plug assembly 15 may further comprise a data logger holder plug 801. Data logger holder plug 801, which is also shown separately in FIGS. 27A through 27C, may be a unitary (i.e., one-piece) structure comprising a piece of thermally insulating material. Materials suitable for use in making data logger holder plug 801 may include, for example, expanded polystyrene foams, polyurethane foams, and/or expanded polypropylene foams. A particularly preferred material may be an open cell urethane foam having a density of 1.50±0.15 lb/ft³. Even though, in the present embodiment, data logger holder plug 801 is a one-piece monolayer structure, it is to be understood that data logger holder plug 801 may comprise multiple layers of similar or different materials and/or may be made by joining together a plurality of pieces.

Data logger holder plug 801, which may be dimensioned to fit snugly within a rear portion of transverse opening 777 of data logger 771, may be a generally rectangular member shaped to include a front 803, a back 805, a bottom 809, a top 811, a left side 813, and a right side 815.

Data logger holder plug 801 may function to substantially close the rear of opening 777 in data logger holder 771, thereby minimizing thermal loss through opening 777. Data logger holder plug 801 may be removably or permanently secured within data logger holder 771 and may be so secured using any suitable chemical and/or mechanical means.

Without wishing to be limited to any particular dimensions, illustrative dimensions for data logger holder plug 801 may include the following: a width from bottom 809 to top 811 of approximately 1.875 in; a length from left side 813 to right side 815 of approximately 4 in; and a thickness from front 803 to back 805 of approximately 0.5 in.

Door plug assembly 15 may further comprise a pair of receiver recess plugs 831-1 and 831-2. Receiver recess plugs 831-1 and 831-2 may be identical to one another; thus, the discussion below of receiver recess plug 831-1 may be equally applicable to receiver recess plug 831-2. Receiver recess plug 831-1, which is also shown separately in FIGS. 28A through 28C, may be a unitary (i.e., one-piece) structure comprising a piece of thermally insulating material. Materials suitable for use in making receiver recess plug 831-1 may include, for example, expanded polystyrene foams, polyurethane foams, and/or expanded polypropylene foams. A particularly preferred material may be an open cell urethane foam having a density of 1.50±0.15 lb/ft³. Even though, in the present embodiment, receiver recess plug 831-1 is a one-piece monolayer structure, it is to be understood that receiver recess plug 831-1 may comprise multiple layers of similar or different materials and/or may be made by joining together a plurality of pieces.

Receiver recess plug 831-1, which may be dimensioned to matingly fit within a front portion of recess 629 of plug 603, may be a generally rectangular member shaped to include a front 833, a back 835, a bottom 839, a top 841, a left side 843, and a right side 845.

Receiver recess plugs 831-1 and 831-2 may function to substantially close the front of recesses 629 and 631, respectively, thereby minimizing thermal losses through recesses 629 and 631. Receiver recess plugs 831-1 and 831-2 may be removably or permanently secured within recesses 629 and 631, respectively, and may be so secured using any suitable chemical and/or mechanical means.

Without wishing to be limited to any particular dimensions, illustrative dimensions for receiver recess plug 831 may include the following: a width from bottom 839 to top 841 of approximately 5.5 in; a length from left side 843 to right side 845 of approximately 8 in; and a thickness from front 833 to back 835 of approximately 0.5 in.

Referring now to FIG. 29 , there is shown a front perspective view of an alternative data logger holder to data logger holder 771, the alternative data logger holder being represented generally by reference numeral 851.

Data logger holder 851 may be identical to data logger holder 771 in size, shape and composition, except that, whereas data logger holder 771 may have a transverse opening 777, data logger holder 851 may instead have a transverse opening 853. Transverse opening 853 may differ in length and width from transverse opening 777 but may have a similar thickness. For example, whereas transverse opening 777 may have a length (in the direction from left side 773 to right side 775) of approximately 4 in and a width of approximately 1.875 in (in the direction from bottom 779 to top 781) for transverse opening 777, transverse opening 853 may have a corresponding length of approximately 3.5 in and may have a corresponding width of approximately 2.125 in. As can readily be appreciated, data logger holder 851 may be suitable where a data logger is to be used whose external length and width dimensions are similar to the length and width dimensions of transverse opening 853 whereas data logger holder 771 may be suitable where a data logger is to be used whose external length and width dimensions are similar to the length and width dimensions of transverse opening 777. Consequently, depending on the data logger to be used, one may use either data logger holder 771 or data logger holder 851. It is to be understood that additional alternative data logger holders having the same external dimensions as data logger 771 but a differently sized transverse opening may be used for data loggers of other external length and width dimensions. Therefore, depending on the data logger to be used, one may incorporate into door plug assembly 15 a corresponding data logger holder without having to replace any of the other components of door plug assembly 15. FIG. 30 shows a data logger holder plug 861 that may be matingly received within a rear portion of transverse opening 853 of data logger holder 851. Data logger holder plug 861 may have a length of approximately 3.5 in, a width of approximately 2.125 in, and a thickness of approximately 0.5 in.

To assemble door plug assembly 15, one may insert a data logger (not shown) and data logger plug 801 into data logger holder 771 and may insert said combination into transverse opening 623 of plug 603. (The wire from the data logger may be inserted through transverse opening 683-1 or 683-2 of rear backing sheet 607.) One may additionally insert handle insert plugs 731-1 and 731-2 into handle inserts 701-1 and 701-2, respectively, and may insert said combination into transverse openings 625 and 627, respectively, of plug 603. One may additionally insert receive recess plugs 831-1 and 831-2 into recesses 629 and 631 of plug 603. One may additionally secure front backing sheet 605 and rear backing sheet 607 to the front and rear surfaces, respectively, of plug 603.

Once assembled, door plug assembly 15 may be transported, installed in shipper 13 and/or removed from shipper 15 by popping out pop-out handles 665 and 667 and inserting one’s hands through pop-out handles 665 and 667 and into handle inserts 701-1 and 701-2.

It is to be understood that, even though door plug assembly 15 is disclosed herein as being completely removable from shipper 13, door plug assembly 15 could be hingedly attached or slidably attached to shipper 13. Also, it is to be understood that, although shipper 13 is described herein as having a door at the front of the frame, the door need not be located at the front of the frame, but rather, could be located at other portions of the frame, such as at the back of the frame, at the left side of the frame, at the right side of the frame, at the top of the frame, or at the bottom of the frame, and that door plug assembly 15 could be adapted for where the door may be positioned at such other locations.

Some additional features, aspects and/or advantages that may apply to at least some embodiments of door plug assembly 15 are identified below.

-   ● Door plug assembly 15 may provide additional door sealing     insulation for higher thermal performance. -   ● Door plug assembly 15 may have rigid plastic front backing sheet     605 and/or rear backing sheet 607, enabling easy handling of large     foam plug 603 and/or enabling consistent seal forces on interface to     system ID. -   ● Door plug assembly 15 may have handles that enable easy insertion     and removal of door plug assembly 15, with cutouts for hands but     still insulated in back (due to handle insert plugs 731-1 and     731-2). -   ● Front backing sheet 605 of door plug assembly 15 may provide a     surface for branding and customer instructions. -   ● Adjustable or alternative data logger cavities may ensure precise     data logger placement and protection during transit to enable     consistent temperature readings. -   ● Door plug assembly 15 may provide handles in two places. -   ● Front backing sheet 605 may have a recess to enable kickstand 561     to push into plug 603. -   ● Recesses 629 and 631 at bottom of plug 603 and recesses 685-1 and     685-2 at bottom of rear backing sheet 607 may provide clearance for     buckles 555 of payload retaining members 551-1 and 551-2 to access     receivers 557-1 and 557-2 on the floor of shipper 13 but may not be     through holes due to receiver recess plugs 831-1 and 831-2.

As discussed above, shipper 13 may include door-latching mechanism 240 in which the hooked end 265-1 of the upper locking finger 255 may extend through opening 262-1 of the upper frame plate 259 and may engage the rear surface of the upper frame plate 259 and in which the hooked end 265-2 of the lower locking finger 255 may extend through opening 262-2 of the lower frame plate 259 and may engage the rear surface of the lower frame plate 259. As can readily be appreciated, the proper operation of door-latching mechanism 240 requires that hooked end 265-1 of locking finger 255 be alignable with opening 262-1 of upper frame plate 259 and that hooked end 265-2 of locking finger 255 be alignable with opening 262-2 of lower frame plate 259 so that hooked ends 265-1 and 265-2 may be inserted through openings 262-1 and 262-2, respectively, when door 37 is to be latched shut and so that hooked ends 265-1 and 265-2 may be withdrawn through openings 262-1 and 262-2, respectively, when door 37 is to be opened. When shipper 13 is seated on a surface that is substantially even or flat, the necessary alignment of hooked ends 265-1 and 265-2 with openings 262-1 and 262-2 can typically be achieved without a significant problem. On the other hand, when shipper 13 is seated on an uneven surface, shipper 13 may not have sufficient structural rigidity on its own to stay square or to prevent system racking. Instead, shipper 13 may skew in a manner such that left side portion 25 and right side portion 27 may not lie at right angles relative to bottom portion 17 and top portion 19. As a result of this skewing, hooked ends 265-1 and 265-2 may not be alignable with openings 262-1 and 262-2, respectively, to a desired degree. This lack of desired alignability is problematic as it may adversely impact the closure or opening of door 37.

Consequently, according to another aspect of the present invention, the shipping system may further comprise a door brace assembly that may be used to maintain left side portion 25 and right side portion 27 at right angles relative to bottom portion 17 and top portion 19, thereby enabling hooked ends 265-1 and 265-2 to be alignable with openings 262-1 and 262-2, respectively.

Referring now to FIG. 31 , there is shown a partly exploded perspective view of a second embodiment of a shipping system for temperature-sensitive materials, the shipping system being constructed according to the teachings of the present invention and being represented generally by reference numeral 911. Details of shipping system 911 that are discussed elsewhere in this application or that are not critical to an understanding of the invention may be omitted from FIG. 31 and/or from the accompanying description herein or may be shown in FIG. 31 and/or described herein in a simplified manner.

Shipping system 911 may comprise a shipper 913 and a door brace assembly 915. Shipper 913 may be identical to shipper 13, except that shipper 913 may further comprise a sealing gasket 917, which may be mounted within space 29 proximate to the door end of space 29 using fasteners 918.

Door brace assembly 915, which is also shown separately in FIGS. 32A through 32F, may comprise a plug 921, a door brace 923, a front backing sheet 925, and a rear backing sheet 927.

Plug 921, which is also shown separately in FIGS. 33A and 33B, may comprise an assembly of flexible pieces of thermally insulating material, which flexible pieces may be joined together by adhesive or other suitable means. Materials suitable for use in making plug 921 may include, for example, expanded polystyrene foams, polyurethane foams, and/or expanded polypropylene foams. A particularly preferred material may be an open cell urethane foam having a density of 1.50±0.15 lb/ft³. Plug 921 may have a generally rectangular shape and may be dimensioned to fit snugly within the open end of space 29, preferably just inside of door 37, in such a way as to substantially close the open end of space 29. Without wishing to be limited to any particular dimensions for plug 921, plug 921 may have an overall size comparable to that of plug 603.

In the present embodiment, plug 921 may comprise a top piece 931, a bottom piece 933, a left piece 935, and a right piece 937. Each of top piece 931, bottom piece 933, left piece 935, and right piece 937 may be generally triangular, and top piece 931, bottom piece 933, left piece 935, and right piece 937 may be arranged and spaced apart from one another to collectively define a generally rectangular structure having a pair of diagonal channels 939 and 941. As will be discussed further below, diagonal channels 939 and 941 may be used to receive door brace 923. Preferably, there is sufficient clearance between the foam members of plug 921 and door brace 923 to ensure ease of installation, allowing an operator to manipulate door brace assembly 915 into an out-of-square shipper 913. Large clearances also allow door plug 921 of door brace assembly 915 to remain centered in a door frame, ensuring a proper seal between the edge of the foam and the frame.

Plug 921 may further comprise a first front piece 943, which may be used to cover most of the front of channel 939, and first and second rear pieces 945 and 947, which may be used to cover most of the rear of channel 939. Plug 921 may further comprise second and third front pieces 949 and 951, which may be used to cover most of the front of channel 941. Plug 921 may further comprise first and second corner pieces 953 and 955, which may be inserted into channels 939 and 941, respectively, proximate to their top ends.

Top piece 931 may be shaped to include a transverse opening 961. A data logger holder 963, which may be similar or identical to data logger holder 771 (or, alternatively, to data logger holder 851), may be removably or permanently mounted in transverse opening 961. A data logger holder plug 965, which may be similar or identical to data logger holder plug 801 (or, alternatively, to data logger holder plug 861) may be removably or permanently mounted in a rear portion of an opening 967 in data logger holder 963.

Bottom piece 933 may be shaped to include two recesses 971 and 973 along its bottom edge. Recesses 971 and 973, which may be similar or identical to recesses 629 and 631 of plug 603, may be dimensioned so that buckles 555 of payload retaining members 551-1 and 551-2 may access receivers 557-1 and 557-2 on the floor of shipper 913. Receiver recess plugs 981-1 and 981-2, which may be identical to receiver recess plugs 831-1 and 831-2, may be removably or permanently secured within the front portion of recesses 971 and 973, respectively, and may be so secured using any suitable chemical and/or mechanical means.

Door brace 923, which is also shown separately in FIGS. 34A and 34B, may comprise a first strut 1001 and a second strut 1003, wherein first strut 1001 and second strut 1003 may be identical to one another. In the present embodiment, each of first strut 1001 and second strut 1003 may be a unitary, hollow member of rectangular cross-section that is lightweight but possesses high columnar strength. To this end, each of first strut 1001 and second strut 1003 may be made of a lightweight yet rigid material, such as an aluminum alloy or other suitable material. Without wishing to be limited to any particular dimensions or characteristics, each of first strut 1001 and second strut 1003 may have a length of approximately 58.25 in, a wall thickness of approximately 0.13 in, and a weight of approximately 2.82 lb.

As can be seen best in FIG. 35 , first strut 1001 (second strut 1003 being identical thereto) may comprise a first opening 1005 and a second opening 1007, wherein first opening 1005 and second opening 1007 may be aligned with one another. First opening 1005 may have a comparatively larger diameter (e.g., approximately 1 in), and second opening 1007 may have a comparatively smaller diameter (e.g., approximately 0.5 in). Each of first opening 1005 and second opening 1007 may have a center that is approximately 25.5 in from the bottom end of first strut 1001.

First strut 1001 and second strut 1003 may be crossed relative to one another and may be oriented so that their respective second openings 1007 face towards one another and so that their respective first openings 1005 face away from one another. A first fender washer 1011 may be positioned over first opening 1005 of first strut 1001, and a second fender washer 1013 may be positioned over first opening 1005 of second strut 1003. A threaded bolt 1015 may be inserted through first fender washer 1011, first strut 1001, second strut 1003, and second fender washer 1013, and may be held in place with a nut 1017. With first strut 1001 and second strut 1003 coupled in the above manner, struts 1001 and 1003 may be granted three degrees of freedom.

Door brace 923 may further comprise a first lower corner piece 1021, which may be secured to the bottom end of first strut 1001 with a spring pin 1023, and a second lower corner piece 1025, which may be secured to the bottom end of first strut 1003 with a spring pin 1027. As will be discussed further below, first lower corner piece 1021 may be used to engage the lower right corner of the frame of shipper 913, and second lower corner piece 1025 may be used to engage the lower left corner of the frame of shipper 913.

Door brace 923 may further comprise a first upper corner piece assembly 1031 and a second upper corner piece assembly 1033, wherein first upper corner piece assembly 1031 and second upper corner piece assembly 1033 may be identical to one another. First upper corner piece assembly 1031 may be mounted on first strut 1001 proximate to its top end using threaded bolts 1032 and nuts 1034, and second upper corner piece assembly 1033 may be mounted on second strut 1003 proximate to its top end using threaded bolts 1036 and nuts 1038.

First upper corner piece assembly 1031, which is also shown separately in FIG. 36 , may comprise a reverse action clamp 1041. Reverse action clamp 1041 may be conventional in construction and may comprise, amongst other things, a handle 1043, a mounting bracket 1045, and an internally threaded barrel 1047. Handle 1043 is preferably a straight handle so that handle 1043 may be in-line with plug 921 when door brace 923 is actuated and, thus, will not interfere with the closure of door 37. Handle 1043 is preferably relatively long to give comparatively more mechanical advantage to an operator when the operator is using door brace assembly 915 to bring shipper 913 back to square, particularly when the weight of a payload is present.

Movement of handle 1043 from a first position that is generally perpendicular to barrel 1047 to a second position that is generally parallel to barrel 1047 causes barrel 1047 to translate in a direction away from mounting bracket 1045. Mounting bracket 1045 may be coupled to first strut 1001 with a pair of threaded bolts 1032 and may be held in place by nuts 1034.

First upper corner piece assembly 1031 may further comprise an upper corner piece 1061. Upper corner piece 1061, which may be made of molded plastic or a similarly suitable material, may be shaped to engage the upper left corner of the frame of shipper 913. Upper corner piece 1061 may have a transverse opening through which a threaded bolt 1063 may be inserted. Bolt 1063 may also be inserted through a washer 1067, a first locknut 1069, and a second locknut 1071, and a bottom end 1073 of bolt 1063 may be screwed into barrel 1047. Washer 1067 and first locknut 1069 allow upper corner piece 1061 to be pushed against the head of bolt 1063 while still being able to spin freely. This allows bolt 1063 to screw in and out of barrel 1047 without spinning upper corner piece 1061, thereby enabling finer adjustments. Once bolt 1063 is in proper position, second locknut 1071 can lock bolt 1063 into place.

Front backing sheet 925, which is shown separately in FIGS. 37A and 37B, may be a unitary (i.e., one-piece) structure comprising a rigid or stiff sheet of material, such as a sheet of corrugated polypropylene, and may be similar in construction to front backing sheet 605. (Even though, in the present embodiment, front backing sheet 925 is a one-piece monolayer structure, it is to be understood that front backing sheet 925 may comprise multiple layers of similar or different materials and/or may be made by joining together a plurality of pieces.) Front backing sheet 925 may have a footprint that is slightly smaller than that of plug 921. Front backing sheet 925 may be generally centered relative to the front of plug 921.

Front backing sheet 925 may be a generally rectangular member and may be shaped to include a front 1101, a back 1103, a bottom 1105, a top 1107, a left side 1109, and a right side 1111. Front backing sheet 925 may further be shaped to include a transverse opening 1113, which may be generally rectangular in shape and which may be aligned with transverse opening 961 of plug 921 to permit access to a data logger mounted in transverse opening 961. Front backing sheet 925 may also be shaped to include a pair of recesses 1115-1 and 1115-2, which may be aligned with first upper corner piece assembly 1031 and second upper corner piece assembly 1033, respectively, to permit access thereto and to accommodate handles 1043 in their engaged or flat position. Front backing sheet 925 may further be shaped to include a cut-away portion 1117 along a lower portion of right side 1111. Cut-away portion 1117, which may be generally rectangular in shape, may be used to receive kickstand 561 (i.e., to allow kickstand 561 to be pressed against the more compressible plug 921 to ensure that door 37 may close). Front 1101 of front backing sheet 925 may provide a suitable surface for branding and/or instructions for use of door brace assembly 915.

Rear backing sheet 927, which is shown separately in FIGS. 38A and 38B, may be a unitary (i.e., one-piece) structure comprising a rigid or stiff sheet of material, such as a sheet of corrugated polypropylene, and may be similar in construction to rear backing sheet 607. (Even though, in the present embodiment, rear backing sheet 927 is a one-piece monolayer structure, it is to be understood that rear backing sheet 927 may comprise multiple layers of similar or different materials and/or may be made by joining together a plurality of pieces.) Rear backing sheet 927 may have a footprint that is slightly smaller than that of plug 921. Rear backing sheet 927 may be generally centered relative to the back of plug 921.

Rear backing sheet 927 may be a generally rectangular member and may be shaped to include a front 1151, a back 1153, a bottom 1155, a top 1157, a left side 1159, and a right side 1161. Rear backing sheet 927 may further be shaped to include a pair of transverse openings 1163-1 and 1163-2, both of which may be aligned with transverse opening 961 of plug 921. Transverse openings 1163-1 and 1163-2 may be generally circular in shape. One or both of transverse openings 1163-1 and 1163-2 may be used to pass wiring from a data logger that is mounted within plug 921 to an interior location within space 29. Rear backing sheet 927 may also be shaped to include a pair of recesses 1165-1 and 1165-2 along its bottom edge. Recesses 1165-1 and 1165-2, which may be generally rectangular in shape, may be substantially aligned with recesses 971 and 973 of plug 921 and may be dimensioned so that buckles 555 of payload retaining members 551-1 and 551-2 may access receivers 557-1 and 557-2 on the floor of shipper 913. Rear backing sheet 927 may also be shaped to include a pair of transverse openings 1171-1 and 1171-2. Transverse openings 1171-1 and 1171-2 may be dimensioned and positioned to receive tightening hardware associated with payload retaining members 551-1 and 551-2. Rear backing sheet 927 may also be shaped to include a transverse opening 1173. Transverse opening 1173 may be used to receive mounting bracket 1045 of second upper corner piece assembly 1033 to reduce the overall thickness of assembly 915, thereby ensuring that door 37 may close properly.

Front backing sheet 925 and rear backing sheet 927 may be removably or permanently secured to the front and rear faces, respectively, of plug 921 using any suitable chemical and/or mechanical means and may serve to provide stiffening support to plug 921, which otherwise may be incapable of self-support or which may exhibit poor self-support.

To operate door brace assembly 915, both handles 1043 may begin in a retracted position (i.e., handles 1043 generally perpendicular to plug 921 as shown in FIG. 39 ). The operator may then grab both handles 1043 in the retracted position and push handles 1043 in a direction towards one another, thereby causing the bottom ends of struts 1001 and 1003 to scissor towards one another. (Preferably, channels 939 and 941 are dimensioned to allow for such a scissoring movement of struts 1001 and 1003.) This movement may then cause first lower corner piece 1021 and second corner lower piece 1025 to be retracted slightly into channels 939 and 941, respectively. With first lower corner piece 1021 and second corner lower piece 1025 thus retracted, door brace assembly 915 may be positioned within the frame of shipper 913. (Handles 1043 may be used to carry and install door brace assembly 915.) The scissoring force applied to handles 1043 may then be ceased, thereby causing first lower corner piece 1021 and second corner lower piece 1025 to return to their original positions, where they may make contact with the lower corners of the frame of shipper 913. Handles 1043 may then be swung in-line with plug 921, thereby causing upper corner pieces 1061 to engage the upper corners of the frame of shipper 913 with sufficient force to cause the frame of shipper 913 to be brought back to square. Typically, prior to use, door brace assembly 915 may be calibrated for use with its associated shipper 913 so that the deployment of door brace 923 is sufficient to bring the frame of shipper 913 back to square.

As can be appreciated, although door brace assembly 915 may include, amongst other things, a plug, front and rear backing sheets, and a data logger holder, door brace assembly 915 could be modified to omit one or more of the plug, the front and rear backing sheets, and the data logger holder. For example, the plug may be omitted where the thermal protection that it provides is not needed. Also, although not shown, the shipping system of the present invention could include separate door plug and door brace assemblies, with one assembly located in front or behind the other.

The embodiments of the present invention described above are intended to be merely exemplary and those skilled in the art shall be able to make numerous variations and modifications to it without departing from the spirit of the present invention. All such variations and modifications are intended to be within the scope of the present invention. 

What is claimed is:
 1. A shipping system for temperature-sensitive materials, the shipping system comprising: (a) an insulated container, the insulated container having a payload space dimensioned to accommodate a payload and further having a door leading to the payload space; and (b) a door plug assembly, the door plug assembly being positioned within the payload space just inside the door, the door plug assembly comprising a plug and a first backing sheet, the plug being thermally insulating and dimensioned to substantially close the payload space when the door is open, the first backing sheet coupled to the plug to provide stiffening support thereto.
 2. The shipping system as claimed in claim 1 wherein the shipping system is a passively-controlled shipping system.
 3. The shipping system as claimed in claim 1 wherein the door plug assembly is removable from the insulated container.
 4. The shipping system as claimed in claim 1 wherein the first backing sheet is secured to a front surface of the plug.
 5. The shipping system as claimed in claim 1 wherein the first backing sheet is secured to a rear surface of the plug.
 6. The shipping system as claimed in claim 1 wherein the door plug assembly further comprises a second backing sheet, wherein the first backing sheet is secured to a front surface of the plug, and wherein the second backing sheet is secured to a rear surface of the plug.
 7. The shipping system as claimed in claim 1 wherein the plug comprises one or more pieces of flexible foam insulation.
 8. The shipping system as claimed in claim 1 wherein the first backing sheet comprises corrugated polypropylene.
 9. The shipping system as claimed in claim 1 wherein the plug comprises at least one transverse opening.
 10. The shipping system as claimed in claim 9 wherein the at least one transverse opening comprises a handle opening.
 11. The shipping system as claimed in claim 10 further comprising a handle insert, the handle insert being disposed within the handle opening and being configured to receive a hand of a user.
 12. The shipping system as claimed in claim 11 further comprising a handle insert plug, the handle insert plug being disposed within the handle insert to minimize air flow through the handle insert.
 13. The shipping system as claimed in claim 12 wherein the first backing sheet is secured to a front surface of the plug and comprises an opening aligned with the handle opening of the plug.
 14. The shipping system as claimed in claim 9 wherein the at least one transverse opening comprises a data logger opening.
 15. The shipping system as claimed in claim 14 further comprising a data logger holder, the data logger holder being disposed within the data logger opening.
 16. The shipping system as claimed in claim 11 further comprising a data logger holder plug, the data logger holder plug being disposed within the data logger holder to minimize air flow through the data logger holder.
 17. The shipping system as claimed in claim 16 wherein the first backing sheet is secured to a front surface of the plug and comprises an opening aligned with the data logger holder.
 18. The shipping system as claimed in claim 1 wherein the insulated container further comprises a kickstand mounted on the door, wherein the first backing sheet is secured to a front surface of the plug, and wherein the first backing sheet is configured to include a recess for receiving the kickstand.
 19. The shipping system as claimed in claim 1 wherein the insulated container further comprises a strap terminating in a buckle and further comprises a receiver and wherein the plug is shaped to include a recess to permit access to the receiver by buckle.
 20. A kit, the kit comprising: (a) an insulated container, the insulated container having a payload space dimensioned to accommodate a payload and further having a door leading to the payload space; (b) a door plug, the door plug being thermally insulating and dimensioned to substantially close the payload space when the door is open, the door plug having a first transverse opening; (c) a first data logger holder, the first data logger holder being dimensioned to matingly receive a first type of data logger; and (d) a second data logger holder, the second data logger holder being dimensioned to matingly receive a second type of data logger, the second type of data logger having different outer dimensions than the first type of data logger; (e) wherein the first data logger holder and the second data logger holder have the same outer dimensions and are alternatively mountable in the first transverse opening of the plug.
 21. The kit as claimed in claim 20 further comprising a first data logger holder plug and a second data logger holder plug, wherein the first data logger holder plug is mountable within the first data logger holder and wherein the second data logger holder plug is mountable within the second data logger holder.
 22. The kit as claimed in claim 20 wherein the door plug comprises at least one piece of flexible foam insulation.
 23. The kit as claimed in claim 22 further comprising at least one of a first backing sheet secured to a front surface of the door plug and a second backing sheet secured to a rear surface of the door plug.
 24. A shipping system for temperature-sensitive materials, the shipping system comprising: (a) an insulated container, the insulated container comprising a frame surrounding a payload space, the frame including a door providing access to the payload space; and (b) a door brace, the door brace removably mounted within the payload space just inside the door, the door brace configured to keep the frame square.
 25. The shipping system as claimed in claim 24 wherein the shipping system is a passively-controlled shipping system.
 26. The shipping system as claimed in claim 24 wherein the shipping system is a pallet-sized shipping system.
 27. The shipping system as claimed in claim 24 further comprising a door plug, the door plug being thermally insulating and dimensioned to substantially close the payload space when the door is open.
 28. The shipping system as claimed in claim 27 wherein the door plug comprises a plurality of assembled pieces of foam insulation.
 29. The shipping system as claimed in claim 28 wherein the door brace is mounted within the door plug.
 30. The shipping system as claimed in claim 27 wherein the door plug comprises a transverse opening and wherein the shipping system further comprises a data logger holder, the data logger holder being mounted in the transverse opening.
 31. The shipping system as claimed in claim 24 wherein the door brace comprises a first strut and a second strut and wherein the door brace further comprises a first corner piece, a second corner piece, a third corner piece, and a fourth corner piece, the first corner piece being fixedly mounted at a bottom end of the first strut, the second corner piece being fixedly mounted at a bottom end of the second strut, the third corner piece being coupled to a top end of the first strut with a reverse action clamp, and the fourth corner piece being coupled to a top end of the second strut with a reverse action clamp.
 32. The shipping system as claimed in claim 31 wherein the first strut and the second strut are joined in a scissoring configuration. 